The present invention relates to non-stationary high power EV fast charger operating with a storage battery system that is replenished by solar energy, capable of providing EV fast charging services to EVs where they are stranded, such as but not limited to solar energy based mobile Electric Vehicle (EV) fast charger system.
At the starting of the 21st century, the awareness for electric and other alternative fuel vehicles has increased due to growing concern over the problems that associate with hydrocarbon-fueled vehicles harming to the environment caused by their emissions and the sustainability of the current hydrocarbon-based transportation infrastructure. However the shortcoming of electrical vehicles (EV) is the limitation of driving range on their fully charged batteries and charging time. The range is usually between 60 to 300 miles per charge and charging time is between 8 hours to 10 hours or more, resulting in that EVs can be stranded on the road if their batteries are depleted or there is no EV charging station nearby. Therefore, high power mobile EV fast charger system is much needed to ease those emergency situations.
The techniques disclosed in Pat. Application WO 2012178010 A1, U.S. Pat. No. 6,979,913 B2 and U.S. Pat. No. 7,057,303 B2 represent the prior art of mobile EV chargers. However these prior art systems use regular fossil fuel power generator as power source. They suffer two major drawbacks: (1) since they use gasoline powered generator to produce AC power, they emit CO2 harming the environment and causing significant reduction of Mile Per Gallon Equivalent (MPGe) of EV, which severely cut the benefit of EV itself and even defeat the purpose of using EV; (2) they merely produce AC power and relie on EV on board charger (OBC) to charge EV battery which would take hours due to its small charger. Therefore, it is ideal to provide solar energy based high power mobile EV fast charger to eliminate pollution, increase the MPGe of EV and decrease charging time effectively.
The object of this invention is to provide a pollution free, high efficient and high power solar energy based mobile EV fast charger (SE-MEVFC) system that offers EV fast charging service in minutes rather than hours to EVs where they are stranded on the road or in remote area.
One non-limiting aspect of the present invention contemplates a high power solar energy based mobile EV fast charger (SE-MEVFC) comprising three sections: 1. A high power mobile EV fast charger with a multi-function power conversion system (MFPCS), an universal battery interface system, an on-board battery system, an alternator power interface, and an alternator power source all mounted on a service truck; 2. a stationary solar power system with a solar power source, an AC power source, a MFPCS, LCL filter plus an isolation transformer, and multiple DC inductors interfaced with on-board battery system in mobile EV fast charger; 3. numerous system operation modes: EV fast charger with on-board battery mode (Mode 1), EV battery charger with truck alternator mode (Mode 2), on-board battery charger with truck alternator mode (Mode 3), on-board battery charger with solar power generation mode (Mode 4), an interleaved multi-phase on-board battery charger mode (Mode 5), on-board battery charger with AC grid power mode (Mode 6).
One non-limiting aspect of the present invention contemplates a MFPCS to provide DC/DC, DC/AC, AC/DC power conversion hardware functions comprising a three phase IGBT module mounted on a liquid cooled heatsink, connected to a DC-link capacitor, and controlled by a IGBT gate drive circuit card, a DSP interface circuit card, a Texas Instrument (TI) DSP control Card; a DC current sensor, three primary current sensors.
One non-limiting aspect of the present invention contemplates TI DSP control card to provide power conversion and battery charger software functions comprising Mode 1 control library comprising isolated EV fast charger control algorithms, Mode 2 control library comprising isolated EV fast charger control and DC/DC boost converter control algorithms, Mode 3 control library comprising DC/DC boost EV fast charger control algorithms, Mode 4 control library comprising three phase grid-tied inverter control plus direct on-board battery charger control algorithms, Mode 5 control library comprising interleaved multi-phase battery charger control algorithms, Mode 6 control library comprising PWM rectifier battery charger control algorithms.
One non-limiting aspect of the present invention contemplates high frequency (HF) isolated EV fast charger control algorithms to charge EV battery with on-board battery system comprising EV battery data base of voltage, current, temperature, state of charge (SOC), age, chemistry, charging requirements for all EV battery system, battery voltage and current control means, DC current control means, full bridge PWM means.
One non-limiting aspect of the present invention contemplates DC/DC boost converter control algorithms to regulate the DC-link voltage of mobile EV battery charger with truck alternator power comprising a DC voltage control means, a boost current control means, a boost PWM means.
One non-limiting aspect of the present invention contemplates DC/DC boost EV fast charger control algorithms to charge on-board battery with truck alternator power comprising battery voltage and current control means, a boost current control means, a boost PWM means.
One non-limiting aspect of the present invention contemplates three phase grid-tied inverter control plus direct on-board battery charger control algorithms to produce AC grid power and charge on-board battery with solar power directly at station when solar power is greater than battery voltage (VMP>VB) comprising maximum power point tracking (MPPT) means, DC voltage control means, battery charging power calculation means, AC current reference generation means, AC current control means, and Space Vector Modulation (SVM) means.
One non-limiting aspect of the present invention contemplates interleaved multiphase battery charger control algorithms to charge on-board battery with solar energy at station when solar power is less than battery voltage (VMP<VB) comprising an optimal solar energy tracking means, an battery voltage control means, a multiphase DC current control means, and interleaved multi-phase PWM means.
One non-limiting aspect of the present invention contemplates PWM rectifier battery charger control algorithms to convert AC grid power to DC charging on-board battery at station comprising battery voltage and current control means, AC current generation means, AC current control means and SVM means.
One non-limiting aspect of the present invention contemplates a mobile EV fast charger with on-board battery mode (Mode 1) comprising a configuration of HF isolated EV battery charger (when MFPCS connecting to on-board battery and universal battery interface which connecting to EV battery) and Mode 1 control library.
One non-limiting aspect of the present invention contemplates a mobile EV battery charger with truck alternator mode (Mode 2) comprising a configuration of a single phase boost converter (when one phase leg of MFPCS connecting to alternator power through a boost inductor), a HF isolated EV fast battery charger (when the other two phase legs of MFPCS connecting to universal battery interface which further connecting to EV battery) and Mode 2 control library.
One non-limiting aspect of the present invention contemplates an on-board battery charger with truck alternator mode (Mode 3) comprising a single phase boost battery charger configuration (when one phase leg of MFPCS connecting to alternator power through a boost inductor and to on-board battery) and Mode 3 control library.
One non-limiting aspect of the present invention contemplates an on-board battery charger with solar power generation mode (Mode 4) comprising a three phase grid tied inverter and direct on-board battery charger configuration (when solar power voltage is greater than battery voltage (VMP>VB) and with MFPCS connecting to stationary solar panels and on-board battery and to stationary LCL filter and isolation transformer which further connecting to AC grid power) and Mode 4 control library.
One non-limiting aspect of the present invention contemplates an interleaved multi-phase battery charger mode (Mode 5) comprising a three phase interleaved battery charger configuration (when solar power voltage is less than battery voltage (VMP<VB) and with MFPCS connecting to solar energy source through intermedium of multiple DC inductors and to on-board battery) and Mode 5 control library.
One non-limiting aspect of the present invention contemplates an on-board battery charger with AC grid power mode (Mode 6) comprising a PWM rectifier battery charger configuration (when MFPCS connecting to on-board battery and to LCL filter plus an isolation transformer which connecting to AC grid power source) and Mode 6 control library.
One non-limiting aspect of the present invention contemplates a universal battery interface system operable to charge any type of EV batteries comprising re-configurable high frequency (HF) transformer means, transformer re-configuration switch means, diode rectifier means, and output L-C filter means.
One non-limiting aspect of the present invention contemplates re-configuration HF transformers to provide galvanic isolation and universal battery voltage arrangement comprising one primary winding and two secondary windings with a turns ratio of n; primary winding connected in parallel while secondary windings placed in combination of series and/or parallel connections resulting in rescaling turns ratio to matching any EV voltage range.
One non-limiting aspect of the present invention contemplates transformer re-configuration switch means comprising transformer re-configuration control table which determines the relationship between effective transformer turns ratio and EV battery voltage ranges.
One non-limiting aspect of the present invention contemplates a mobile EV fast charger comprising an user interface allowing user to select EV model from EV battery data base or a communication interface allowing direct communication between mobile EV fast charger and EV when EV is in charging service, so as to setting right hardware configuration and launching corresponding battery charger control algorithms before battery charging process begins.
One non-limiting aspect of the present invention contemplates a solar energy based mobile EV fast charger (SE-MEVFC) system capable of charging EV battery in minutes and quickly re-loading solar energy to its on-board storage battery through a stationary solar energy system and its unique system configuration comprising: SE-MEVFC operating as EV fast charger with on-board battery in mode 1; SE-MEVFC operating as EV battery charger with truck alternator in mode 2; SE-MEVFC operating as on-board battery charger with truck alternator in mode 3; SE-MEVFC operating as on-board battery charger with solar power generation in mode 4; SE-MEVFC operating as interleaved multi-phase battery charger in mode 5; and SE-MEVFC operating as on-board battery charger with AC grid power in mode 6.
The present invention is pointed out with particularity in the appended claims. However, other features of the present invention will become more apparent and the present invention will be best understood by referencing to the following detailed description in conjunction with the accompany drawings in which:
As required, detailed embodiments of the present invention are disclosed herein; However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
A primary current sensing system 38 and a DC current sensing 40 may be included to facilitate sensing currents provided to primary winding of HF transformer in universal EV fast charger 12 or to LCL filter plus isolation transformer 26 in a three-phase single stage battery charger 24 and to DC input. The DSP interface card 44 may condition and filter feedback from current sensor 38, 40 and other sensing devices within the system, and provide the feedback signals to TI control card 46 for further processes. The TI control card 46 with Mode 1 control library 48, Mode 2 control library 50, Mode 3 control library 52, Mode 4 control library 54, Mode 5 control library 178, and Mode 6 control library 192 may cooperate with DSP interface card 44 and IGBT gate drive 42 to control IGBT module 32 such that the opening and closing switches 56, 58, 60, 62, 64, 66 can be coordinated to produce the desired voltage/current waveform patterns for DC/DC, DC/AC and AC/DC power conversions.
Universal battery interface system 18 illustrated in
The output voltage amplitude of a MFPCS based universal EV fast charger 12 (In
In control algorithms 98, an user interface 114 may be included allowing the operator of a mobile EV super charger to select the EV model from EV battery data base 100 so that the corresponding hardware configuration and battery charging control algorithms are selected before the battery charging process begin. In control algorithms 118, a communication interface 116 which establishes an instant communication between a mobile EV fast charger and a EV when they are connected, may automatically reconfigured the hardware and select battery charging control algorithms before the battery charging process begin.
In the functional block diagram of PWM rectifier charger control algorithms 120 as illustrated in
In the functional block diagram of DC/DC boost converter control algorithms 134 as illustrated in
In the functional block diagram of DC/DC boost battery charger control algorithms 144 as illustrated in
In the functional block diagram of three phase grid-tied inverter plus direct on-board battery charger control algorithms 156 as illustrated in
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention, rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without depart from the sprit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
This application claims the benefit of U.S. Provisional Application 62/350,982 and hereby incorporates the application by reference.
Number | Date | Country | |
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62350982 | Jun 2016 | US |