EV Charging Port Matrix With Remote Converters and Shared Cooling
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Solution Overview
Problem
Charging stations with multiple ports face issues of high power consumption, noise, inefficiency, and increased costs due to the need for multiple DC/DC converters to handle different inlet voltages, which limits simultaneous charging and requires extensive cooling facilities.
Innovation Solution
A charging system with a switchable connection matrix and remote power converters, allowing simultaneous charging of multiple vehicles with galvanic isolation, modular expansion, and shared cooling systems, reducing hardware and noise at the charging location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple DC/DC converters are placed before each charging port to handle different inlet voltages, then simultaneous charging of multiple vehicles is enabled, but the cost of the charging station increases
Solution Approach 1:
A single DC/DC converter is designed to serve multiple charging ports by dynamically adjusting its output voltage and current parameters. The converter can adapt to different vehicle requirements (different inlet voltages) through control circuitry that modifies its operating parameters, eliminating the need for dedicated converters at each port while maintaining simultaneous charging capability
Solution Approach 2:
The charging system employs dynamic parameter adjustment where the DC/DC converter's output characteristics (voltage, current) are continuously modified based on real-time requirements of connected vehicles. This dynamic adaptability allows one converter to replace multiple static converters, reducing system cost while preserving productivity
2Reliability
If forced cooling facilities are installed for each power converter to prevent overheating, then component damage from overheating is prevented, but the charging station becomes noisy and energy efficiency decreases
Solution Approach 1:
Multiple power converters share a common cooling facility instead of each converter having its own dedicated cooling system. The merged cooling system reduces the total number of cooling components, thereby reducing noise levels and improving energy efficiency while still providing adequate thermal management for all converters through centralized airflow or liquid cooling
Solution Approach 2:
A single cooling facility is designed to serve multiple power converters simultaneously. The cooling system can dynamically adjust its capacity and distribution to match the thermal loads of different converters, providing reliable overheating protection across all components while minimizing noise and energy consumption through optimized resource utilization
3Productivity
If larger power converters with increased power capacity are used, then the ability to charge multiple vehicles simultaneously is improved, but larger cooling facilities are required which increase noise and reduce energy efficiency
Solution Approach 1:
The charging system is divided into multiple modular power converter units, each with moderate power capacity. These segmented converters can operate independently or in combination, allowing the system to scale charging capacity without requiring a single large converter that would demand extensive cooling infrastructure. Each module has its own optimized cooling requirements, reducing overall noise and improving energy efficiency
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
Enables efficient, cost-effective, and noise-free simultaneous charging of multiple vehicles with flexible expansion capabilities, minimizing hardware upgrades and cooling disturbances.
Implementation Method 1
a plurality of power converters for converting power from a power source to a desired format for charging the vehicle
Implementation Method 2
a switchable connection matrix for connecting at least one power converter to at least one charging port
Data Source
AI summary
A charging system for electric vehicles is disclosed, which includes at least one charging port with an interface for power exchange with at least one electric vehicle, and at least one power converter for converting power from a power source such as a power grid to a suitable format for charging the vehicle. The power converter can be at a remote location from the charging port, such as a separate room, and/or a separate building.