EV Charging Dispenser Chains for Space-Constrained Fleet Infrastructure
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in providing a large number of charging dispensers in limited spaces, such as parking areas and fleets, due to the limitations of standard power cabinets and conduit space requirements, especially during peak charging hours like overnight.
Innovation Solution
The implementation of a charging system with a power cabinet and dispenser chains, where each dispenser chain consists of multiple electrically coupled dispensers that can be controlled to provide power sequentially, allowing for efficient distribution of power to multiple vehicles using a master controller and communications hub, enabling more dispensers to connect to a single power cabinet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a standard power cabinet is used with limited power modules, then the cabinet size and conduit space are reduced, but the number of dispensers that can be connected is limited
Solution Approach 1:
The system segments the power distribution function by introducing dispenser chains where dispensers are electrically coupled in series. Each dispenser chain can be independently controlled, allowing multiple dispensers to share a single power cabinet's output. This segmentation enables one power cabinet to serve multiple dispensers without requiring proportional increases in cabinet size or power module count.
Solution Approach 2:
The power cabinet is designed with universal output capabilities that can serve multiple dispensers through chained connections. The dispenser chains provide multi-functionality by allowing a single power module to sequentially or simultaneously power multiple dispensers, making the power cabinet adaptable to varying numbers of vehicles and charging demands without reconfiguration.
2Quantity of substance
If multiple power cabinets are installed to provide more dispensers, then the number of available charging outlets increases, but the space required for cabinets and supply line conduits increases
Solution Approach 1:
The system merges multiple dispenser functions into a single power cabinet by implementing dispenser chains. Multiple dispensers are electrically coupled in series to a single power module, consolidating what would traditionally require multiple separate cabinets into one unified unit. This merging dramatically reduces the physical footprint while maintaining the ability to serve multiple vehicles.
Solution Approach 2:
The patent transitions from a one-to-one mapping of power cabinets to dispensers to a one-to-many relationship through dispenser chains. By adding the dimensional aspect of series electrical coupling, the system enables a single power cabinet to distribute power along a chain of multiple dispensers, effectively expanding capacity without proportional increases in physical space.
3Quantity of substance
If more power modules are added to increase dispenser capacity, then the number of connected dispensers increases, but the power cabinet size increases
Solution Approach 1:
The system segments the power distribution architecture by creating dispenser chains that can be electrically coupled to existing power modules. Rather than adding more power modules to serve additional dispensers, the system segments the dispenser load into chains that share power module capacity through controlled sequential or simultaneous operation, maintaining cabinet volume while increasing dispenser count.
4Productivity
If a large number of dispensers are provided for fleet charging, then all vehicles can be charged during off hours, but the number of required power cabinets increases
Solution Approach 1:
The power cabinet achieves universality by designing it to serve multiple dispensers through chained electrical couplings. A single power cabinet with appropriate controller configuration can manage multiple dispenser chains, providing fleet-scale charging capacity without requiring a proportional increase in the number of power cabinets. The system adapts to different fleet sizes and charging demands through software control rather than hardware proliferation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for the charging of multiple vehicles simultaneously while optimizing space and reducing the number of required power cabinets, enhancing charging efficiency and economics by enabling up to 20 vehicles to be charged from a single cabinet with peak power outputs exceeding 300 kW.
Implementation Method 1
converting AC electrical power to DC electrical power by the charging station
Data Source
AI summary
A charging station includes an alternating current (AC) electrical power input and at least one direct current (DC) electrical power module coupled to the AC electrical power input. The charging station also includes at least one station output having a vehicle DC electrical power output, a communications output, and a dispenser DC electrical power output, the dispenser DC electrical power output being configured to be coupled to at least one dispenser. The charging station further includes a communications hub including at least one communications network connection, the communications hub being configured to receive information relating to an amount of DC electrical power to be delivered to a particular dispenser coupled to the charging station. Further still, the charging station includes a master controller configured to receive the information from the communications hub relating to the amount of DC electrical power to be delivered to the particular dispenser coupled to the charging station and provide a control signal to one of the at least one DC electrical power modules, the control signal being based on the information and being configured to control the amount of DC electrical power sent through one of the at least one DC electrical power modules.