Integrated EVSE Charging System with AC/DC Coupler
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Solution Overview
Problem
Current Electric Vehicle Supply Equipment (EVSE) charging systems are limited by the inability to simultaneously provide Alternating Current (AC) and Direct Current (DC) power to vehicles, leading to underutilization of charging equipment and increased cost, mass, and complexity in high-power charging systems.
Innovation Solution
An EVSE charging system that includes an AC voltage bus, a coupler capable of supplying both AC and DC power, an offboard charging module to convert AC to DC, and a relay to selectively provide either AC or DC power, controlled by an EVSE controller to ensure compatibility and optimize energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If AC and DC charging equipment are used separately, then charging capability is provided, but equipment cost, mass, and complexity increase
Solution Approach 1:
The patent combines separate AC charging equipment and DC charging equipment into a single integrated EVSE system. The system includes an AC voltage bus, DC voltage bus, coupler, offboard charging module, and relay that work together to provide both AC and DC charging capabilities through one unified device, thereby reducing overall equipment complexity while maintaining full charging functionality.
Solution Approach 2:
The integrated EVSE system is designed to perform multiple functions: it can deliver AC power to the vehicle through the coupler, convert AC to DC via the offboard charging module and deliver DC power through the same coupler, and switch between these modes using relays. This multi-functional design allows one piece of equipment to replace what would traditionally require separate AC and DC charging stations.
2Adaptability or versatility
If AC and DC charging equipment are used separately, then charging capability is provided, but equipment mass increases
Solution Approach 1:
The patent merges AC charging equipment and DC charging equipment into a single integrated system, sharing common components such as the coupler, control electronics, and structural framework. By consolidating these separate systems into one unified device, the total mass of charging equipment is reduced while maintaining the ability to provide both AC and DC charging capabilities.
3Adaptability or versatility
If AC and DC charging equipment are used separately, then charging capability is provided, but equipment cost increases
Solution Approach 1:
The integrated EVSE system combines AC and DC charging equipment into one unit, allowing for shared manufacturing processes, common components (coupler, control system, housing), and consolidated assembly operations. This merging reduces the total number of parts that need to be manufactured and assembled, thereby lowering production costs compared to manufacturing separate AC and DC charging systems.
Solution Approach 2:
The system employs universal components that serve multiple functions. For example, the coupler is used for both AC and DC power delivery, the offboard charging module can operate in different charging modes, and the control system manages both AC and DC charging operations. This multi-functionality reduces the total component count and simplifies manufacturing, leading to cost reductions.
4Power
If only DC charging equipment is used, then high power charging is achieved, but equipment heaviness and complexity increase
Solution Approach 1:
The patent segments the charging system into distinct functional modules: an AC charging path with AC voltage bus and relay, a DC charging path with DC voltage bus and offboard charging module, and a control system with EVSE controller. This segmentation allows the system to provide high-power DC charging when needed while maintaining the option for AC charging, and reduces complexity by organizing components into manageable, independently controllable modules.
Solution Approach 2:
The system dynamically switches between AC charging mode and DC charging mode using relays controlled by the EVSE controller. When high power charging is required, the relay switches to connect the DC voltage bus and offboard charging module for DC power delivery. When lower power charging suffices, the system operates in AC mode. This dynamic operation allows the system to provide high-power capability when needed while avoiding the constant complexity of having both paths fully active simultaneously.
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 simultaneous AC and DC power delivery to vehicles, reducing the overall equipment needed for high-power charging, thereby minimizing cost, mass, and complexity while optimizing energy transfer efficiency.
Implementation Method 1
an offboard charging module (OBCM) electrically connected to the EVSE AC voltage bus. The OBCM is configured to convert the AC power to the DC power
Data Source
AI summary
An Electric Vehicle Supply Equipment (EVSE) charging system that can simultaneously deliver both Alternating Current (AC) and Direct Current (DC) power to Plug-in Electric Vehicle's (PEV) AC voltage bus and DC voltage bus, respectively. Either a Combined Charging System (CCS) coupler or separate paired AC and DC couplers provide the connection between the EVSE's vehicle connector(s) and the PEV's inlet(s). The EVSE is configured to simultaneously supply AC and DC power to the vehicle when connected to the PEV. The EVSE coupler(s) facilitate communication between a PEV and the EVSE charging system when connected to the charging inlet(s) of the PEV. Connection of the AC voltage bus to the PEV is controlled by one or more relays, while and connection of the DC voltage bus to the PEV is controlled by operation of an Offboard Charging Module (OBCM).