Vehicle-Based DC Charging Using Single-Phase Grid Power
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Solution Overview
Problem
Existing EV charging systems face challenges in providing high-power charging at residential and light industrial sites due to the limitations of single-phase power grids, which are costly and time-consuming to upgrade to support fast charging needs.
Innovation Solution
Repurpose an electric vehicle (EV) as a charger (VAAC) using its existing components, such as the DC battery pack and AC to DC converter, to enable high-power DC charging between EVs, leveraging single-phase AC power grids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single-phase AC power grid is used for EV charging, then charging infrastructure is accessible at residential and light industrial sites, but charging power is limited to less than 50 KW
Solution Approach 1:
The patent merges the AC power grid connection with a DC battery storage system to create a hybrid charging solution. The system combines single-phase AC input with a DC battery pack and DC-DC converter to deliver high-power DC charging output, effectively combining multiple power sources to overcome the limitations of single-phase AC power.
Solution Approach 2:
The DC battery pack and DC-DC converter act as intermediary components between the single-phase AC power grid and the EV charging port. These intermediaries enable power conversion and amplification, transforming limited single-phase AC power into high-power DC charging output without requiring grid upgrades.
2Power
If 3-phase 480 V grid service is upgraded to provide fast charging power above 50 KW, then charging power increases to meet fast charging demands, but infrastructure cost and implementation time increase significantly
Solution Approach 1:
The patent uses a portable, modular charging system that can be deployed without permanent infrastructure changes. The vehicle-mounted charging system uses existing EV components (battery pack, converter) that can be moved and repositioned, avoiding the need for expensive, fixed 3-phase grid infrastructure while providing equivalent charging capability.
Solution Approach 2:
The system changes the power delivery parameters by using DC-DC conversion to transform the voltage and power characteristics. Instead of relying on high-voltage AC infrastructure, the system uses battery voltage and DC conversion to achieve high-power charging through different electrical parameters, bypassing the need for grid upgrades.
3Ease of manufacture
If existing EV components are repurposed for charging other EVs, then component utilization increases and new infrastructure cost decreases, but system complexity increases
Solution Approach 1:
The patent makes EV components universal by enabling them to serve multiple functions. The DC battery pack and converter that originally served the vehicle's propulsion needs are repurposed to also function as a charging station for other EVs, creating a multi-functional system that reduces the need for dedicated charging infrastructure.
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 high-power DC charging without the need for expensive grid upgrades, utilizing automotive-grade components efficiently and providing a second-use opportunity for EV components, while allowing simultaneous charging and discharging capabilities.
Implementation Method 1
an AC to DC converter, for example, an on-board charger module (OBCM), connected to the AC charging port and the battery pack and is capable of providing DC power to the battery pack from the AC power grid
Data Source
AI summary
Various embodiments of a charging system for charging an electric vehicle (EV) are disclosed. One embodiment, among others, is charging system in the form of an EV. The EV has (1) an electric propulsion, direct current (DC) battery pack designed to provide electrical power to a plurality of electric motors for propulsion of the EV; (2) a DC charging port that is connected to the DC battery pack; (3) an alternating current (AC) charging port connected to a single-phase AC power grid associated with a utility service provider; (4) an on-board charger module (OBCM) connected to the AC charging port and the battery pack and providing DC power to the battery pack from the AC power grid; A point-of-sale (PoS) dispenser receives DC power from the DC charging port. The dispenser has a coupler that is connectable to and dis-connectable from an EV to be charged.