Variable-Speed Alternator Charging for Off-Grid EV DC Fast Charge
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Solution Overview
Problem
The existing electrical grid is inadequate to support the rapid growth of electric vehicle charging demands, requiring a significant upgrade in infrastructure, which is costly and inefficient, and conventional charging systems rely on internal combustion engine generators operating outside their efficient speed range, leading to inefficiencies and environmental concerns.
Innovation Solution
A DC fast charging arrangement that uses an internal combustion engine or generator driving an alternator connected to a voltage regulator, with an engine control unit communicating with a charging controller and battery management system to adjust voltage and speed for optimal charging, allowing for variable speed operation and direct DC voltage delivery to the vehicle batteries, eliminating the need for expensive charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the existing electrical grid is used to support electric vehicle charging, then charging infrastructure is available, but the grid capacity is inadequate and would require costly triple or quadruple upgrade to support mass EV charging
Solution Approach 1:
The patent extracts the charging function from the centralized electrical grid infrastructure and places it at the individual vehicle level through onboard generation systems. This eliminates the need for extensive grid upgrades by making each vehicle self-sufficient for charging needs.
Solution Approach 2:
The patent introduces an onboard generator and alternator system as an intermediary between the vehicle battery and external power sources. This intermediary enables fast charging without requiring the electrical grid to be upgraded, bridging the gap between available grid power and vehicle charging needs.
2Power
If conventional internal combustion engine generators are used for charging, then power can be generated, but the engine operates outside its efficient speed range leading to inefficiencies
Solution Approach 1:
The patent makes the engine operating speed dynamic by allowing it to vary within its efficient range based on charging demands. The engine speed is no longer fixed but adjusts dynamically to maintain optimal efficiency while meeting power requirements, resolving the contradiction between power delivery and efficiency.
Solution Approach 2:
The patent changes the operating parameters of the engine by introducing variable speed capability and optimizing the operating range. This allows the engine to operate at efficient speeds while still providing the necessary charging power, transforming the fixed-speed operation into a flexible parameter system.
3Productivity
If high voltage DC fast charging is provided through charging stations, then fast charging capability is achieved, but expensive charging station equipment and extensive infrastructure installation are required
Solution Approach 1:
The patent extracts the fast charging capability from centralized charging stations and integrates it directly into the vehicle through onboard generation and power conversion systems. This eliminates the need for expensive charging station infrastructure while maintaining fast charging productivity.
Solution Approach 2:
The patent creates a universal charging solution that works independently of external charging infrastructure. The onboard system can provide fast charging anywhere, making the vehicle self-sufficient and eliminating dependency on specialized charging stations and their complex infrastructure.
4Power
If the electrical grid is upgraded to support mass EV charging, then sufficient power capacity is available, but years of installation time and massive infrastructure investment are required
Solution Approach 1:
The patent performs preliminary action by equipping vehicles with onboard generation capabilities before any grid upgrade is needed. This allows EVs to be charged immediately without waiting for infrastructure development, reversing the traditional sequence where charging capability depends on prior grid expansion.
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
This solution enables efficient and cost-effective fast charging of electric vehicles by optimizing engine speed and voltage based on battery conditions, reducing the need for extensive grid upgrades and minimizing environmental impact, while supporting multiple vehicle charging capabilities.
Implementation Method 1
The alternator is driven by the internal combustion engine to produce either of a single or multi-phase AC voltage
Implementation Method 2
The rectifier converts the AC voltage from the alternator to a DC voltage
Data Source
AI summary
Embodiments described herein are directed to a charging assembly for use with a battery. The assembly includes an engine, a voltage regulator, an engine control unit, a charging controller, and a rectifier. The engine drives an alternator for producing either of a single or multi-phase AC voltage. The voltage regulator communicates with said alternator. The rectifier converts the AC voltage from the alternator to DC prior to delivery to the battery pack. The engine operates at variable speeds during charging of the battery, including an initially higher revolutions per minute corresponding to a highest rate of charge when a current charge of the battery is at or below a predetermined threshold level, with a subsequently reduced revolutions per minute as a temperature of the battery is rising and the current charge of the battery is increasing, during which the rate of charge slows as directed by the battery management system.