EV Charging System with Electrical and Thermal Storage
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Solution Overview
Problem
Existing charging systems for electric vehicles cannot achieve high charging speeds due to insufficient electrical network power and excessive heat generation at high charging rates, which limits the charging power to less than 300 kW and results in inefficient energy transfer and thermal management.
Innovation Solution
A charging system that incorporates an electrical storage device and a thermal storage device connected to a re-cooling apparatus, allowing for high-speed charging by leveraging electrical network power and efficiently dissipating heat through thermal re-cooling, with the electrical and thermal storage devices matched in capacity and dynamics to support high-power charging operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If DC charging mode is used to increase charging speed, then charging power is improved, but heat generation increases excessively
Solution Approach 1:
A thermal storage device acts as an intermediary between the power electronics and the environment. It temporarily stores thermal energy generated during high-power charging operations and releases it when cooling capacity is available, decoupling the heat generation from immediate heat dissipation requirements and enabling sustained high charging powers.
Solution Approach 2:
The system dynamically adjusts operating parameters including charging power levels, cooling medium flow rates, and thermal storage device states. By changing these parameters in response to thermal conditions, the system optimizes the balance between charging speed and thermal management, allowing operation at high powers when thermal conditions permit.
2Productivity
If electrical network power is increased to achieve higher charging speeds, then charging speed is improved, but infrastructure complexity and cost increase
Solution Approach 1:
Electrical energy is stored in advance in electrical storage devices during periods of lower demand or available capacity. This preliminary energy accumulation allows the charging station to deliver high charging speeds without requiring continuous high-capacity electrical network infrastructure, as the energy is pre-stored and ready for rapid discharge when needed.
Solution Approach 2:
Electrical storage devices serve as intermediaries between the electrical network and the charging station. They buffer the mismatch between network power availability and charging demand, allowing the system to achieve high charging speeds without proportionally increasing network infrastructure complexity and cost.
3Temperature
If thermal storage capacity is increased to improve heat dissipation, then thermal management is improved, but system size and cost increase
Solution Approach 1:
The thermal management system is designed to be dynamic rather than statically oversized. The thermal storage device capacity, cooling medium flow rates, and re-cooling apparatus operation are dynamically adjusted based on real-time thermal conditions and charging power levels, allowing adequate thermal management with a more compact system than would be required for worst-case continuous operation.
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 charging speeds exceeding 300 kW while effectively managing heat dissipation, ensuring efficient energy transfer and prolonged system reliability, allowing multiple vehicles to be charged quickly and safely.
Implementation Method 1
at least one electrical storage device which is connected between the electrical current and voltage supply network and the respective charging station in such a manner that said storage device can be charged on the basis of the electrical network power
Implementation Method 2
at least one thermal storage device which is connected to the re-cooling apparatus, to the respective charging station, to the power electronics and to the, or each, electrical storage device in such a manner that said storage device or a cooling medium of said storage device can be heated on the basis of the power loss
Implementation Method 3
a re-cooling apparatus, the respective charging station, the power electronics and the, or each, electrical storage device being connected to the re-cooling apparatus which provides a defined thermal re-cooling power
Implementation Method 4
power electronics, the respective charging station being able to be connected, with the interposition of the power electronics, to an electrical current and voltage supply network
Data Source
AI summary
Charging system for electric vehicles, having: a charging station to which a traction battery of an electric vehicle can be coupled via a charging cable; power electronics, the charging station being able to be connected, with the interposition of the power electronics, to an electrical current and voltage supply network which provides a defined electrical network power; an electrical storage device which is connected between the electrical current and voltage supply network and the charging station such that said storage device is charged on the basis of the electrical network power and is discharged on the basis of a charging speed of the charging station; a re-cooling apparatus, the charging station, the power electronics and the electrical storage device connected to the re-cooling apparatus which provides a defined as thermal re-cooling power; a thermal storage device connected to the re-cooling apparatus, to the charging station, to the power electronics and to the electrical storage device such that said storage device or a cooling medium of said storage device is heated on the basis of the power loss of the power electronics, charging station and electrical storage device and can be cooled on the basis of the thermal re-cooling power of the re-cooling apparatus.