Integrated EV Charging With Shared DC Bus and Flexible Modes
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Solution Overview
Problem
Conventional electric vehicle charging systems face challenges such as poor scalability, high costs, and difficulty in integrating DCFCs with level two AC chargers due to infrastructure limitations, especially in existing facilities with limited space and mismatched AC grid voltages, leading to costly upgrades and inefficiencies.
Innovation Solution
An integrated electric charging system with an energy storage subsystem and a charging subsystem that includes power converters and operational switches, allowing for flexible operation in DC and AC modes, and the ability to share power between systems, reducing reliance on AC grid infrastructure and accommodating various voltage levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If DC fast charging subsystems are integrated with level two AC charging subsystems in existing facilities, then charging functionality is improved, but infrastructure upgrade costs increase due to mismatched AC grid voltages and limited space
Solution Approach 1:
The patent combines DC fast charging subsystem and level two AC charging subsystem into a single integrated charging system that shares common infrastructure including AC input ports, power converters, control units, and housing. This merging eliminates duplicate infrastructure requirements and reduces overall upgrade costs while providing both DC and AC charging functionalities.
Solution Approach 2:
The integrated charging system is designed to perform multiple functions: it can operate as a DC fast charger, a level two AC charger, or both simultaneously. The system includes configurable charging ports and power converters that can adapt to different charging modes, making it universally applicable to various charging needs without requiring separate dedicated infrastructure for each charging type.
2Productivity
If DC fast charging is deployed in existing facilities with limited space, then charging capacity is improved, but device complexity increases due to integration requirements
Solution Approach 1:
The system merges DC and AC charging subsystems into a single integrated unit that shares common components such as AC input ports, power converters, control units, and housing structures. This consolidation increases charging capacity within limited space while managing integration complexity through unified system architecture.
Solution Approach 2:
The integrated charging system employs a nested architecture where the DC fast charging subsystem and level two AC charging subsystem are housed within a common housing structure. The subsystems share nested common infrastructure including power converters, control units, and mounting mechanisms, allowing compact arrangement that maximizes space utilization while organizing complexity hierarchically.
3Adaptability or versatility
If separate DC and AC charging systems are installed, then charging mode flexibility is improved, but scalability is reduced due to infrastructure limitations
Solution Approach 1:
The patent merges separate DC and AC charging systems into a single integrated unit that provides both charging modes. This consolidation maintains charging mode flexibility while improving scalability by reducing infrastructure footprint and enabling easier deployment in existing facilities with limited capacity.
Solution Approach 2:
The integrated charging system provides universal functionality by incorporating both DC fast charging and level two AC charging capabilities in a single deployable unit. This multi-functionality enhances scalability as the system can be installed in various locations without requiring separate infrastructure for each charging mode, allowing broader deployment across different facilities.
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
The system enhances scalability, reduces costs by minimizing infrastructure upgrades, and efficiently manages peak power demands through flexible voltage management and power sharing, enabling deployment in existing facilities without the need for extensive renovations.
Implementation Method 1
an energy storage subsystem for storing direct current (DC) power
Implementation Method 2
one or more power converters, each power converter having a DC side couplable to the common DC bus, the one or more power converters being operable to maintain a voltage of the common DC bus at a pre-defined DC voltage level
Implementation Method 3
the one or more power converters being operable to maintain a voltage of the common DC bus at a pre-defined DC voltage level
Data Source
AI summary
Various example embodiments are provided herein relating to integrated electric charging systems and methods of operating thereof. In at least one example, there is provided an integrated electric charging system, comprising: an energy storage subsystem for storing direct current (DC) power; a charging subsystem coupled to the energy storage subsystem and comprising: a common DC bus; one or more power converters, each power converter having a DC side couplable to the common DC bus, the one or more power converters operable to maintain a voltage of the common DC bus at a pre-defined DC voltage level; and at least one operational switch interposed between the one or more power converters, wherein the operational switch varies an operational mode of the integrated charging system.