Modular EV Charger Architecture for Field Upgrades Across Charging Types
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current EV charging infrastructure lacks the ability to be modularly upgraded from pure AC or DC charging to a combination of DC, AC, and Wireless charging, requiring full replacement and resulting in costly losses of existing investment.
Innovation Solution
A modular and field upgradable EV charger topology featuring a common communications module connected to individual AC, DC, and wireless charging modules, allowing for addition or replacement of modules without replacing the base chassis or altering grid connectivity, enabling future upgrades to combined charging types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If charging equipment is replaced in the field to support new standards, then the charging station can support new charging technologies, but the existing investment is lost and replacement costs are incurred
Solution Approach 1:
The charging station is divided into modular components: a base unit and interchangeable charging modules. Each module (AC charging module, DC charging module, wireless charging module) can be independently installed, removed, or replaced. This segmentation allows the system to adapt to different charging standards by simply swapping modules rather than replacing the entire charging station, thereby preserving existing investment while maintaining adaptability to new standards.
Solution Approach 2:
The base charging station unit is designed with universal interfaces and communication protocols that can work with multiple types of charging modules. The common communication module and control system serve multiple functions across different module types, enabling a single base unit to support AC charging, DC charging, and wireless charging through module interchangeability, thus avoiding the need for complete replacement when upgrading standards.
2Adaptability or versatility
If a full charging station replacement is performed to support combined DC, AC and Wireless charging, then the charging station achieves future-proof capability, but the cost increases significantly
Solution Approach 1:
The charging station is divided into modular components: a base unit and interchangeable charging modules. Each module (AC charging module, DC charging module, wireless charging module) can be independently installed, removed, or replaced. This segmentation allows the system to adapt to different charging standards by simply swapping modules rather than replacing the entire charging station, thereby preserving existing investment while maintaining adaptability to new standards.
Solution Approach 2:
The base charging station unit is pre-configured with universal communication interfaces, control systems, and physical mounting structures that are designed to accommodate multiple module types from the outset. This preliminary preparation of the base unit enables future module upgrades without requiring system replacement, allowing customers to start with a single module type and easily add or switch to other module types as needed, thereby reducing overall upgrade costs.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A modular and field upgradable infrastructure device is provided for electric vehicle (EV) charging. The infrastructure device comprises a common communications and control module/a common meter/power module that can be connected to individual charging modules. It further comprises one or more AC, DC and wireless charging modules as internal or external pluggable devices. The common communications and control module is coupled to the AC, DC and wireless charging modules such that the infrastructure device communicates with an EV using power line communications via a protocol or several protocols.