Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
  • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
  • H02J7/34—Parallel operation in networks using both storage and other dc sources, e.g. providing buffering
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
  • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
  • B60L53/50—Charging stations characterised by energy-storage or power-generation means
  • B60L53/53—Batteries
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
  • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
  • H02J7/0029—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
  • H02J7/00304—Overcurrent protection
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
  • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
  • H02J7/0029—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
  • H02J7/00308—Overvoltage protection
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02T90/10—Technologies relating to charging of electric vehicles
  • Y02T90/12—Electric charging stations
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02T90/10—Technologies relating to charging of electric vehicles
  • Y02T90/14—Plug-in electric vehicles

Definitions

• the invention relates to a charging station for charging electric energy storages of electric vehicles, such as cars, motorbikes, buses, trucks, trains, or boats to name a few.
• the invention also relates to a method for charging electric energy storages of charging electric vehicles.
• Electric vehicles use one or more electric motors for propulsion.
• an electric vehicle comprises a battery for storing electrical energy and to power the electric motors, this battery has to be charged from time to time.
• Most electric vehicles are equipped with an internal charger, which has to be connected to an external power source for charging the battery.
• an external power source is for example the power socket connected to the public power grid, for example at home in the garage.
• the invention therefore also relates to charging stations not only for on board batteries of electric vehicles but also where batteries of electric vehicles are separated from the electric vehicle to be re-charged.
• a charging system for electric vehicles which is connected with a AC/DC inverter to an AC grid.
• the charging system comprises a buffer battery having a significantly higher charge capacity than the vehicle battery to be charged.
• a DC/DC inverter, which is connected to the buffer battery can be temporarily connected to the vehicle to charge the vehicle.
• US 2016/0339788 Another system for charging an electric or hybrid-electric vehicle is known from US 2016/0339788, which comprises a low power grid interface.
• the low power grid interface converts AC power provided by the low power grid to DC current at a predetermined voltage for charging a battery buffer.
• the battery buffer is connected to a DC-DC converter, operates to convert the voltage of the battery buffer into an electric vehicle charging voltage for charging the vehicle.
• a charging station for charging electric energy storages of electric powered vehicles comprising an input circuit for connecting the charging station to an electrical power source and providing a first intermediate DC voltage DCi at a first DC output at a first DC voltage level; at least one DC/DC converter which receives the first intermediate DC voltage DCi and which provides at a DC/DC converter output a second DC voltage DC 2 at a second DC voltage level; an electrical DC charging buffer connected to the DC/DC converter; an output circuit for converting the second intermediate DC voltage DC 2 to the DC current or AC current requested by for example an on board battery of an electric vehicle.
• the invention further comprises a control circuit which is adapted to measure an output current provided by the at least one of the DC/DC converter, to determine on basis of the measured output current the power consumed by the input circuit, and to control at least one of the electrical current consumed from the power source, the electrical current provided by the at least one DC/DC converter, the electrical current provided internally for charging the electrical DC buffer, such that the power consumed by the input circuit does not exceed a predetermined level.
• the predetermined level is for example set to the maximum power that a consumer is entitled by his contract with the energy supplier to consume on an average basis or a maximum basis.
• the predetermined level may be set to the value allowed by an overcurrent protection circuit the charging station is connected to.
• the invention proposes to convert an input voltage of any power source, whether a AC power source or a DC power source, to a first intermediate DC voltage and further to convert the first intermediate DC voltage into a second intermediate DC voltage.
• the DC output part of the input circuit acts as a first intermediate DC circuit, wherein the first intermediate DC voltage is buffered, for example with buffer capacitors.
• the first intermediate DC voltage is then distributed via the DC/DC converters to the DC charging buffers.
• the DC charging buffer which may be seen as a part of a second intermediate DC circuit, which distributes the second intermediate DC voltage to the output circuit.
• intermediate DC circuit shall denote in this application circuitry with buffer capabilities, whether the buffers are capacitors, coils, batteries, or whatever elements that can for a short time or a long time keep electrical charges at a nearly constant level.
• Two intermediate DC voltages respectively two intermediate DC circuits, increase the stability of the charging station and allow for a higher degree of flexibility, especially when a not predetermined number of charging points/charging interfaces are combined in a single charging station, i.e. in a single housing.
• the term "charging module” shall denote the logical combination of a DC/DC converter, a second intermediate DC circuit, and an output circuit for generating the charging current from the second intermediate DC voltage of the second intermediate DC circuit.
• the invention allows for an easier heat dissipation management, but also adds greater flexibility when higher currents / higher voltages should be introduced in a later stage for charging the electrical storages of electrical vehicles.
• the charging stations have to be equipped only with modified output circuits and very likely the input circuits and DC/DC converters can be continued to be in use without substantial changes.
• the modification of the output circuit it should suffice to apply a software upgrade for changing the control signals for the control of switching elements. Physically only the interfaces, e.g. plugs or sockets might need a mechanical exchange or add-on. This provides a perfect upgrade path for future standards or quasi standards.
• the distribution of the electrical functions over at least a first intermediate DC circuit and at least one charging module also allows for easy provision of multiple charging modules without the risk that any of the input circuits is electrically overloaded.
• Several input circuits can be connected in parallel with their DC outputs, i.e. the outputs of the first intermediate DC circuits at the first DC voltage level on the common first intermediate DC power rail in case the power source to which the several input circuits are connected to provides more power than a standard power supply.
• several charging modules can be connected with their DC input to the common first intermediate DC power rail of the first intermediate DC circuit/circuits.
• the number of charging modules that can be connected to the common first intermediate DC power rail is not limited to a specific number, although the increased charging time for each additional energy buffer of a charging module imposes a practical limit at which a charging station with too many output circuits in respect to the available input power of the energy source renders the charging station impracticable to use and not economic with view on the costs.
• a control circuit of the charging station is configured to measure an output current provided by the at least one DC/DC converter, to determine on basis of the measured output current the power consumed by the input circuit, and to control the current provided by the at least one DC/DC converter such that the power consumed by the input circuit does not exceed a predetermined level.
• control circuit measures the sum of all output currents of the individual DC/DC converters of each charging module, it can determine approximatively the power consumed from the input circuit as the sum of all DC/DC converters output currents. This information is used by the control circuit for example to control the input circuit such that it reduces the power consumed from the external power source. This is especially beneficial when the charging station is powered up and empty energy buffers draw a lot of power.
• the power consumption of the input circuit could for example be controlled by a controllable rectifier build of thyristor instead of diodes for example.
• the thyristors can be pulse width modulated.
• a long control pulse would let pass the full period of a half sinus wave, whereas if the pulses with respect to the zero crossing of the half sinus wave start later, only part of the half sinus wave would be rectified and thus reduces the power that is available after the thyristor bridge.
• control circuit may control the individual DC/DC converters to reduce their output current so that the power consumed by the input circuits is controlled individually for each DC/DC converter. This seems to be the preferred solution for a smooth control of the input circuit once the charging station has transitioned from start-up phase into steady state operation.
• the first intermediate DC voltage DCi is higher than the second intermediate DC voltage DC 2 .
• the output voltage of the first intermediate DC/DC converter is sufficiently lower than the voltage of the power source, so that even when the power source experiences severe voltage drops the voltage of the power source still stays higher than the output voltage of the first intermediate DC/DC voltage.
• the first intermediate DC/DC converter can be implemented as a simple voltage-down converter. Having a very stable first intermediate DC voltage the second intermediate DC circuits are provided with a perfect input voltage for either up-converting or down-converting the second intermediate DC voltage.
• the electrical power source is a public power grid with an AC voltage.
• This invention is especially beneficial for power sources with limited power supply, such as power sockets in a domestic environment, or power supplied to lamp posts. Usually a fuse would interrupt the power supply if a predetermined power limit is exceeded.
• the second intermediate DC voltage is in a range of 100 Volts to 500 Volts, preferably in the range between 400 to 450 Volts.
• a first intermediate DC voltage of almost 325 Volts can be achieved for input circuits connected to single phase current power systems and a first intermediate DC voltage of approximately 565 Volts can be achieved for input circuits connected to three phase power supply systems with rectifiers and smoothing capacitors.
• a good compromise is to down-convert the first intermediate DC voltage of 565 Volts of a input circuit connected to a three-phase AC power grid to about 420 Volts.
• the control circuit 41 may be adapted to control the amplitude of the first intermediate DC circuit voltage.
• the number of DC/DC converter connected to an input circuit is two or more.
• the input circuit comprises a bridge rectifier which as a function of a control input signal is configured to limit the current provided at the first DC output to a predefined level.
• the central control logic may produce at a control output a power control signal for controlling the power consumption of the input module.
• a power consumption limitation may be achieved for example by a bridge rectifier that is designed with thyristors as rectifier diodes.
• thyristors, SCR, triacs, thyratrons, or other such gated diode-like devices can be control with a cutting angle control signal to go into and out of conduction at a predetermined phase of the AC waveform of the AC input signal. Changing the cutting angle controls the current that is admitted through the rectifier.
• control circuit compares current levels signalled to the control circuit with a predetermined current level and generates a control signal to control the bridge rectifier to limit the current provided at the first DC output.
• the input circuit comprises a bridge rectifier which as a function of a control input signal is configured to cut off the electric power source. This aspect of the invention protects the charging station in the event of over voltages occur.
• control circuit is powered by the energy buffer module. This allows in case the input circuit is disconnected from the power source to continue to operate the charging function of the charging station.
• At least a second input circuit is connected with its output to the output of the input circuit.
• This aspect of the invention makes the charging station easily adaptable to different input power offerings. Instead of having to provide different sizes, respectively types of input circuits, only one size/one type of input circuit needs to be produced. In case a power source with a higher power rating is available, only a respective number of input circuits of identical build can be connected with their output DC rail. Thus renders the charging station very scalable.
• a process for charging electric powered vehicles comprises receiving input power from an electrical power source and providing a first intermediate DC voltage DCi at a first DC voltage level; receiving the first intermediate DC voltage DCi and providing a second intermediate DC voltage DC 2 at a second DC voltage level; buffering electrical energy at the second DC voltage level; converting the second intermediate DC voltage (DC 2 ) to a DC current or AC current requested by the electric vehicles.
• steps may be controlled by one or more microcontrollers controlling an input circuit, at least a DC/DC converter circuit and at least an output circuit of a charging station for energy storages of electric vehicles.
• the invention further proposes to distribute the components of a charging station into separate modules.
• FIG. 1 shows a schematic block diagram of a charging station for an electric vehicle according to the invention
• Figure 2 shows a schematic diagram of a second intermediate DC circuit for an electric charger according to the invention
• Figure 3 shows an electric diagram of a second intermediate DC circuit and an output circuit for an electric charger according to the invention.
• Figure 4a shows a full bridge push pull converter
• Figure 4b shows voltage and current diagrams of a full bridge converter
• Figure 5a shows a three phase full bridge push pull converter
• Figure 5b shows voltage and current diagrams for a three phase full bridge push pull converter.
• FIG. 1 shows a schematic overview of a charging station 1 which is electrically connected by an AC input module 3 to a public electrical grid 2, and by a transformer 8 via at least one socket/plug 9b to an electric vehicle 9.
• the AC input module 3 basically comprises a three-phase-bridge which converts the 400 volts of a 3-phase AC to a DC voltage of about 565 volts.
• the DC output voltage of the AC input module 3 forms a first intermediate DC voltage DCi.
• the three-phase bridge is a full bridge, as this reduces the ripples of the first intermediate DC voltage DCi.
• a person skilled in the art also may consider to use a three-phase half bridge for rectification of the input AC power.
• the three-phase full bridge comprises as rectifying elements thyristors (not shown) which can be controlled by an input module control circuit (not shown).
• the input module control circuit may comprise an overvoltage detector (not shown) which blocks the thyristors in the event the voltage of the input AC voltage exceeds a predetermined overvoltage threshold.
• the central control logic 41 may produce at a control output Co a control signal for controlling the power consumption of the input module 3,
• the bridge rectifier of the input module 3 may be designed with thyristors as rectifier diodes.
• thyristors, silicon controlled rectifier, triacs, thyratrons, or other such gated diode-like devices can be controlled with a cutting angle control signal to go into and out of conduction at a predetermined phase of the AC waveform of the AC input signal. Changing the cutting angle controls the current that is admitted through the rectifier.
• the central control circuit 41 may measure the consumption of the individual modules and if the total power consumption would lead to consume more power from the power source 2 than what is technically available, or is made available under contractual constraints, the power control signal Co could be used to limit the power inflow from the power source 2.
• the overvoltage detector may also detect under voltage situations.
• the input module control circuit may comprise current sensing means (not shown) to measure the current drawn by the input module 1 and may limit the input current to a predetermined input current level.
• the information about the power consumed in the various modules of the charging station may be communicated by the other modules of the charging station to the input module control circuit and the input module control circuit may control the input AC current accordingly.
• the input module 3 may also include a power-factor correction circuit (PFC) (not shown) for improving the total harmonic distortion (THD) and electromagnetic interference (EMI) with the connected grid 2.
• PFC power-factor correction circuit
• a DC input module may provide the first intermediate DC voltage from a DC power source such as fuel cell or solar panels.
• a DC power source such as fuel cell or solar panels.
• the power provided by a DC power source may be limited, or even worse may vary for example in case of solar panels with the solar radiation.
• the person skilled in the art readily appreciates that the advantages of the invention are beneficial to all kinds of electrical power sources where the provided power is somewhat limited.
• the first intermediate DC voltage DC-1 is distributed by a first intermediate DC rail 30 to three first intermediate DC circuits 4.
• the DC power rail 30 is depicted as a single line.
• the person skilled in the art readily appreciates that in reality the DC rail 30 comprises a first positive DC power rail DCi+ and a negative DC power rail DCi- as explicitly shown later in Figure 2.
• Each first intermediate DC circuit 4 provides at its respective first intermediate DC output DC 2 a second intermediate DC voltage V D c 2 .
• Each first intermediate DC output DC 2 supplies the second intermediate voltage V D c 2 to a second intermediate DC circuit 5.
• Each first intermediate DC circuit 4 may comprise a control circuit 41 for measuring the current that is provided by each DC circuit 4. As shown in Fig. 1 alternatively a centralized control circuit 41 may control all of the plurality of first intermediate DC circuits 4 by a single control circuit 41. For the purpose of measuring the consumed power the control circuit 41 is connected to first current sensors 42. Each of the first intermediate DC circuits 4 may have its dedicated control circuit 41 or, as shown in Fig. 1 a central control circuit 41 may control all of the plurality of first intermediate DC circuits 4. Additionally or alternatively the control circuit 41 measures by means of voltage sensors (not shown in Figure 1) the second intermediate DC voltage V D c 2 which each DC circuit 4 delivers at its first intermediate DC output DC 2 .
• the first intermediate DC circuit 4 converts the input voltage of the first intermediate DC circuit into an output voltage that is different from the input voltage. Therefore the first intermediate DC circuit 4 may be also termed as a DC/DC converter 4.
• the DC/DC converters 4 are designed as voltage-down converters which convert the first intermediate DC voltage of nominal 565 volts down to the second intermediate DC voltage V D c 2 , which in this embodiment has been chosen to 420 volts.
• a second intermediate DC voltage V D c 2 which is substantially lower than the voltage at the input of the input circuit 2, respectively the first intermediate DC voltage V D ci simplifies the mitigation of voltage drops of the power source 1.
• the DC/DC converter 4 can be designed as a simple voltage down converter.
• the grid voltage needs only to be down- converted to the second intermediate DC voltage V D c 2 and no up-conversion is needed by the DC/DC converters 4.
• the central control logic 41 is adapted to limit the current that is provided to each DC/DC converter 4 such that the sum of the current multiplied with the input voltage of the input circuit 2 does not exceed the nominal power, respectively allowed short term peak power taken in by the input module 3. This ensures that the maximum power input provided by the external power source 2 is not exceeded and avoids that overcurrent protection devices of the external power source 2 are triggered.
• the control circuit is connected with each DC/DC converter 4 with individual power control signals Ci, C 2 , C3. which control the current delivered by each individual DC/DC converter 4.
• a second intermediate DC circuit 5 with an energy buffer module 6 is connected with its input to the output of a DC/DC converter 4.
• the second intermediate DC circuit 5 supplies an output switching circuit 7 with the buffered second intermediate DC voltage V DC 2-
• the output switching circuit 7 supplies a transformer 8 with currents for primary windings of the transformer 8. Secondary windings of the transformer 8 eventually generate the currents to charge the battery of an electric vehicle 9.
• the DC/DC converter 4, the second intermediate DC circuit 5 with an energy buffer module 6, the output switching circuit 7, and the transformer 8 logically form an output circuit, which according to its function is termed within this application as a charging module.
• the idea of the invention is that one or more charging modules, with its DC/DC converter 4 as an input circuit, can be connected to the first intermediate DC power rail 30.
• FIG. 1 shows only one of the three charging modules. All three charging modules are identical.
• Figure 2 shows the second intermediary circuit 5 of a charging module in more detail.
• Each second intermediate DC circuit 5 is provided with a buffer capacitor 52 which smooths the ripples on the output current provided on a second intermediate DC rail 50 by the DC/DC converter 4.
• This buffer capacitor 52 may be chosen to have a capacity of 1500 micro Farad.
• An energy buffer module 6 is also electrically connected with the second intermediate DC voltage rail 50 and provides additional energy if the current consumed by the output switching circuit 7 is higher than the current that is supplied by the respective DC/DC converter 4.
• the energy buffer module 6 may comprise as an energy buffer 60 a lithium- ion battery or a lithium-ion supercapacitor battery.
• any kind of electrical storage element, that is able to provide sufficient capacity and current could be chosen as an energy buffer 60, as for example a redox flow battery.
• the energy buffer 60 should provide a discharge current peak of greater than 50 Amperes and should allow a charge current peak of greater than 10 Amperes.
• the capacity of the electric buffer 60 depends on the energy that the charging station 1 shall provide to the electric vehicle. With the power that were usual at the time of the application a capacity between 10 and 100 kWh is a reasonable choice. With higher charging powers of course the person skilled in the art would choose an electric buffer 60 with an adequate capacity.
• the energy buffer 60 is arranged in an external buffer module 6.
• a discharging resistor R of approximately 10 to 20 Ohms is arranged in close proximity to the energy buffer 60 inside the buffer module 6.
• the discharging switch So By means of a discharging switch So the discharging resistor R can be switched in parallel to the energy buffer 60.
• the discharging switch So is arranged in the second intermediate DC circuit 5 and controlled by second intermediate DC circuit control logic 51.
• the second intermediate DC circuit control logic 51 measures by means of a current sensor 53 the current that flows into the corresponding output module 7, i.e. the sum of the current provided by the respective second intermediate DC circuit 4 and the current provided by the energy buffer 60.
• a voltage sensor 54 measures the voltage at the output 55 of the second intermediate DC circuit 5.
• a energy buffer current sensor 54 measures the current that flows from the second DC power rail 50 into the energy buffer 6, i.e. the charging current for the energy buffer 60, or in case the current flows from the energy buffer 60 to second DC rail 50 this energy buffer current sensor 54 measures the current that the energy buffer 60 supplies as a buffer current to the output 55 of the second intermediate DC circuit 5.
• the first intermediate DC circuit 4 has to be switched off.
• the second intermediate DC circuit control logic 51 is able to evaluate the "health" of the energy buffer 60, i.e. how much capacity the energy buffer has lost due to aging effects.
• the energy buffer current sensor 54 is arranged in the second intermediate DC circuit 4. However it is evident that alternatively it may be also arrange in the energy buffer module 6.
• the discharging resistor R is arranged in close proximity to the energy buffer 60 for enabling heat transfer from the discharging resistor R to the energy buffer 60.
• the second intermediate DC circuit control logic 51 measures the temperature of the energy buffer 60 and compares the measured temperature with a minimum operation temperature of the energy buffer 60. In the event the measured temperature is lower than the operation temperature of the energy buffer 60 the second intermediate DC circuit control logic 51 connects the discharging resistor R with the discharging switch So to the DC rail 50 and uses the discharging resistor R to heat the energy buffer 60 until the energy buffer 60 has reached its operation temperature. This heating is effectively powered by the power grid 2 via the first intermediate DC circuit 4 with a power of approximately 250 W.
• the heating power may even be pulse modulated to adapt an adequate power as a function of the temperature of the energy buffer 60.
• a temperature sensor 61 communicates the temperature of the energy buffer to the second intermediate DC circuit control logic 51.
• all current provided by the respective first intermediate DC circuit 4 flows into the energy buffer and re-charges the energy buffer 6.
• a lithium battery has been chosen as an energy buffer 6 as at the time the lithium battery is able to provide a high discharge current at relatively low cost.
• the lithium battery may be equipped with a battery management system that ensures that all cells of the lithium -ion battery are on an equal voltage level.
• the person skilled in the art would choose the most appropriate energy buffer 6 for a special application. It is therefore also conceivable to choose a bank of super capacitors for the energy buffer 6, if costs are a less concern.
• the second intermediate DC voltage V D c2 in this embodiment has been chosen to 420 volts to be sufficiently lower than expected voltage drops on the power grid 2.
• the second intermediate DC voltage V D c2 however also depends on the energy buffer 60 that has been chosen for the energy buffer modules 6.
• the concept of the first intermediate DC circuit 4 and the second intermediate DC circuit 5 allows a large range within the second intermediate DC voltage V D c2 can be set. It is for example possible to choose the second intermediate DC voltage V D c2 in- between 100 Volts and 430 Volts in order to accommodate different types of energy buffers 60.
• the central control logic 41 may also be adapted to limit the current provided to second DC/DC modules 5 and thus to limit the charging current of the energy buffer modules 60 for different types of energy buffers 60.
• the central control logic 41 may for example limit the charging current for the energy buffer 60 and/or of the charging power provided by the charging circuits 8 for the charging of a electric vehicle 9 in order to control, respectively limit the power consumption of the input module 3.
• the central control logic 41 may pursuit one out of different strategies.
• the central control logic 41 may provide a constant charging current to all second intermediate DC circuits 5 until the energy buffers have reached for example 90 percent of their capacity and then switch to so-called trickle charge for improving the life and capacity of the energy buffer 60.
• so-called Constant Current - Constant Voltage charging in a first phase the voltage is controlled such that a maximum current is not surpassed. As soon as a predetermined target voltage has been reached, the target voltage will be maintained. Consequently the charging current declines until the battery is fully charged and finally is substantially zero.
• the central logic 41 may alternatively limit the current provided to each second intermediate DC circuit 5 individually according to an internal charging strategy, for example by predominantly re-charging the energy buffer that has the highest charging level among all energy buffers 6 of a charging station. This strategy achieves the object to offer at least one reasonably full buffer 6 at all times. Other strategies are possible, for example always re-filling the buffer 6 with the lowest charge level among all buffers 6 of a charging station 1, which would ensure that all buffers are on a similar charging level.
• the output switching circuit 7 converts the available energy into the electrical power that is requested by the electric vehicle 9.
• several power options and socket varieties for recharging an electric vehicle have to be served.
• most common sockets/plugs options are: a) domestic socket, single phase 230V AC / 10 A / 2.3 kW
• the length of time an electric vehicles batteries take to recharge is limited by the minimum rate between how many kilowatts (kW) the charging station can provide and how many the batteries of the car can accept. It seems that at the time of the application the term “slow charging” is used for charging a vehicles battery from empty to full in around eight hours at an approximate rate of 3kW, for example with a wall charger at home; the term “fast charging” is used for fully replenishing a vehicles batteries in approximately three to four hours at a rate of 5kW to 22kW; and the term “rapid charging” is used for a charging rate of 43kW to lOOkW, which will replenish a vehicles battery to 80% in as little as 30 minutes.
• the flexible concept of the invention allows to arrange its modules and circuits to meet any of the requirements of the listed charging modes. As will be described further down below the flexible architecture of the invention allows to serve most, if not all of these modes and probably most modes that may still emerge.
• the domestic options usually are passive chargers, e.g. the charging station does not exchange any information with the internal charger of the electric vehicle.
• the internal charger communicates with the charging station 1, for example over a dedicated signal wire using for example the so-called CAN bus protocol to control the power provided by the charging station 1.
• the input module 3 and three first intermediate DC circuits 4 are arranged in one module and each second intermediate DC circuit and the respective output module 7 are paired in one module.
• the charging station 1 in this example therefore comes with one housing for the input module 3 and three first intermediate DC circuits 4 in the same housing and three housings each containing a second intermediate DC circuit 5 and an output module 7.
• Each lithium battery 6 is connected to its second intermediate DC circuit 5 and each transformer 8 is separately connected to its respective output module 7.
• the transformer 8 comprises three primary windings L'i, l_' 2 , L'3 and three secondary windings L"i, l_" 2 , L M 3 .
• the output switching circuit 7 comprises six switching elements for controlling the current flow from the second positive intermediate DC rail 50 through the primary windings L'i, l_' 2 , l_' 3 back to the negative DC rail DC-.
• the switching elements are insulated - gate bipolar transistors (IGBT) Ti, T 2 , T 3 , T 4 , T 5 , and T 6 .
• IGBTs combine high efficiency and fast switching at high switching currents.
• IGCT integrated gate-commutated thyristor
• Each transistor Ti, T 2 , T 3 , T 4 , T 5 , T 6 is protected by a free wheeler diode Di, D 2 , D 3 , D 4 , D 5 , D 6 connected with their anode to the emitter of their respective transistor and with their cathode connected to the collector of their respective transistor.
• a pulse width modulation control circuit 71 generates six control signals Bi, B 2 , B3, B 4 , B5, B Q for controlling individually the base of each transistor Ti, T 2 , T3, T 4 , T5, T Q .
• the first secondary winding L"i produces a first output voltage V
• the second secondary winding l_" 2 produces a second output voltage V
• the third secondary winding l_" 3 produces a third output voltage W.
• the first output voltage U, the second output voltage V, and the third output voltage W may be generated with a 120 degree phase offset to form a three-phase AC current, or only two voltages, for example at the second output V and the third output W might be generated leaving the first output basically zero potential.
• filter capacitors may be connected either in a Y-formation or a Delta formation to the three secondary windings L"i, L M 2, L M 3 .
• the filter capacitors usually would have a capacitance of 1 micro Farad.
• An AC/DC mode selector 72 detects which charging voltage/current system is required by an electric vehicle 9 which is connected to the output module 7 and communicates to the pulse width modulation circuit 71 which control signals Bi, B 2 , B 3 , B 4 , B5, B 6 to produce.
• Primary current sensors 71 are provide in each conductor leading to a primary winding L'i, l_' 2 , L'3 for measuring the current provided to each primary winding L'i, l_' 2 , L' 3 .
• the sensor signals of the primary current sensors 71 are forwarded to the pulse width modulation circuit 71 in order to be able to control the current consumed by each primary winding L'i, l_' 2 , l_' 3 .
• secondary current sensors 75 are provided for each secondary conductors U, V, W, N in order to measure the current in each of the secondary conductors U, V, W, N and to provide the information to the pulse with modulation control 71.
• the pulse with modulation control circuit 71 by adjusting the switch on/switch off time of the control signals Bi, B 2 , B 3 , B 4 , B5, B 6 can control the voltage/current to be generated by each secondary windings L"i, l_" 2 , l_" 3 .
• the detected AC/DC mode also controls a first switch Si, a second switch S 2 , a third switch S3 and a fourth switch S 4 to connect or disconnect the first output voltage U, the second output voltage V, and the third output voltage W to respectively from the pins of the sockets, respectively plugs of the charging station 1.
• the AC/DC mode selector connects with the second switch S 2 the first output voltage U to a line conductor pin P of a AC single phase socket/plug.
• the neutral conductor N is permanently connected to a neutral conductor pin N of a single phase socket/plug. In this mode the first switch and the third switch are in off position.
• the plugs served by single phase AC are for example a AC plug according to IEC 62196 Type 2 or a combined AC/DC plug CCS according to IEC 62196. It is evident that also domestic socket outlet or a blue caravan type socket outlet could be served by the charging station of the invention.
• the electric buffer would allow for slow charging several electric vehicles at the same time at a low power outlet, for example from a lamp post.
• the AC/DC mode selector 72 connects all three secondary transformer windings L"i, l_" 2 , L M 3 to the respective pins U, l_ 2 , l_ 3 of the respective charging plug.
• the second switch S 2 and the third switch S3 are in connected position and the first switch Si is in a non-connected position.
• the AC/DC mode selector 72 detects that the connected electric vehicle requires a DC current, the AC/DC mode selector 72 disconnects with the second switch S 2 the first secondary winding L"i from the output conductor U, and disconnects with the third switch S3 the second secondary winding l_" 2 from the second output conductor V.
• the embodiment of Fig. 3 shows a so-called fly back converter.
• the fly back filter 73, 74 is connected to the first secondary winding L"i.
• the fly back filter 73, 74 comprises a fly back diode 73 and a fly back capacitor 74.
• the fly back diode 73 is connected with its anode to the first secondary winding and L"i and with its cathode to the DC output of the vehicle interface 80.
• the fly back capacitor 74 is connected with one of its terminal to the DC charging terminal DC out + of respective plugs of the charging plugs and with its other terminal to the second secondary winding l_" 2 , which at the same time forms the negative charging DC charging terminal DC 0Ut -.
• the winding direction of the first secondary winding L"i is opposite to the winding direction of the second secondary winding l_" 2, which is indicated in Fig. 2 by the dots close to the winding symbols.
• auxiliary switch may be used to connect the terminal of the second secondary winding l_" 2 with the terminal of the third secondary winding l_" 3 in case an even higher DC output voltage has to be achieved.
• the pulse with modulation control 71 also receives a mode signal from the AC/DC mode selector 72 and controls the transistors Ti, T 2 , T 3 , T 4 , T 5 , T 6 , such that either a one phase AC current, a three phase AC current or a DC current at the interface conductors U, V, W, N.
• the control signals generated by the pulse with modulation control 71 in case of a three-phase AC mode control the transistors Ti, T 2 , T 3 , T 4 , T 5 , T 6 are phase- shifted by 120°, the current through the primary windings L'i, l_' 2 , l_' 3 are pulse with modulated in order to control the charging current on the secondary windings of the transformer.
• the primary windings L'i, l_' 2 , l_' 3 of the transformer T r are connected in a triangle and the secondary windings L"i, l_" 2 , l_" 3 of the transformer T r are connected in a start configuration, whereby the common connection of all three winding ends forms the interface conductor N.
• the transformer T r thus achieves a galvanic isolation of the charging current provided at the charging interface from the electric grid 1. It also reduces EMI because the secondary windings L"i, l_" 2 , l_" 3 of the transformer T r is prohibited from introducing high frequency earth currents.
• n 1
• a forward converter lacks efficiency and may not be suited very well for applications that shall provide a charging power above 250 Watts.
• three phase transformers are easily available the following embodiments demonstrate the use of a three phase transformer in connection with push pull converters.
• Fig. 4b shows voltage and current diagrams for the elements of the full bridge push and pull converter.
• the full bridge push and pull converter is connected to the second intermediate positive DC rail DC+ and the second intermediate negative DC rail DC-.
• the voltage between the second intermediate positive DC rail DC+ and the second intermediate negative DC rail DC- is indicated in Fig 4a and Fig. 4b as Ue.
• the output module 7 comprises four switching elements Ti, T 2 , T 3 , and T 4 arranged as a so-called H-bridge.
• the output module 7 generates four control signals Bi, B 2 , B 3 , B 4 such that in a first phase Phi the first switching element Tl and the second switching element T2 are in conductive mode and the third switching element T3 and the fourth switching element T4 are in non- conductive, i.e. blocked mode. This allows for a current to flow from the second intermediate positive DC rail DC+ via the first switching element Tl, the first primary winding L'l, the second switching element T2 to the second intermediate negative DC rail DC-.
• the output module 7 sets the first switching element Tl and the second switching element T2 in non-conductive, i.e. blocked mode and the third switching element T3 and the fourth switching element T4 in conductive.
• This allows for a current to flow from the second intermediate positive DC rail DC+ via the third switching element T3, the first primary winding L'l, the fourth switching element T4 to the second intermediate negative DC rail DC-, but this time the current passes through the primary winding L'l, compared to the first phase, in opposite direction.
• the switching elements are insulated - gate bipolar transistors (IGBT) Tl, T2, T3, and T4.
• each transistor Tl, T2, T3, T4 is protected by a free wheeler diode Di, D 2 , D 3 , D 4 connected with their anode to the emitter of their respective transistor and with their cathode connected to the collector of their respective transistor.
• a free wheeler diode Di, D 2 , D 3 , D 4 connected with their anode to the emitter of their respective transistor and with their cathode connected to the collector of their respective transistor.
• the free wheeler diode Di, D 2 , D 3 , D 4 are not shown in Fig. 4a.
• the first and the second phase Ph2 are generated alternatingly so that the alternating current Ip which flows through the primary winding L'i creates a current with alternating direction in the secondary winding L"i. Between the switching phases a gap has to be maintained, otherwise the switching elements may be conductive at the same time, which would be bare the risk to destroy semiconductor based switching elements.
• a bridge rectifier comprising a first rectifier diode RDi, a second rectifier diode RD 2 , a third rectifier diode RD 3 , and a fourth rectifier diode RD 4 rectify the current of the secondary into a DC current Is, which clearly shows a saw tooth like ramp.
• An output voltage of the bridge rectifier RDi, RD 2 , RD 3 , RD 4 is depicted in the diagrams as Ub.
• an inductance L and a smoothing capacitor C the gaps in the rectified DC current I s and the saw tooth like ripples can be smoothened so that the charging current fluctuates between a lower current amplitude Ii_min and a upper current amplitude Ii_max.
• the inductor L and the smoothing capacitor C perform as a low pass filter of second order.
• a three phase transformer 8 is used as in the embodiment shown in Fig. 3.
• the primary windings L'i, l_' 2 , L' 3 of three phase transformer 8 are exactly as in the embodiment shown in Fig. 3 in a triangle configuration and the secondary winding L"i, l_" 2 , L M 3 of three phase transformer 8 are exactly as in the embodiment shown in Fig. 3 in a star configuration.
• the output module 7 Similar to the embodiment shown in Fig. 3, the output module 7 generates three alternating control signals Bi, B 2 , B 3 , B 4 , B5, B 6 , which operate the switching elements in a B6H configuration.
• the first switching element T1 and the second switching element T2 are in conductive mode and the third switching element T3, the fourth switching element T4, the fifth switching element T5, and the sixth switching elements T6 are in non-conductive, i.e. blocked mode.
• the third switching element T3 and the fourth switching element T4 are in conductive mode and the first switching element Tl, the second switching element T2, the fifth switching element T5, and the sixth switching elements T6 are in non-conductive, i.e. blocked mode.
• the fifth switching element T5 and the sixth switching element T6 are in conductive mode and the first switching element Tl, the second switching element T2, the third switching element T3, and the fourth switching element T4 are in non-conductive, i.e. blocked mode.
• a transformer with more than three primary windings and an adequate number of secondary windings may be used. This allows also for distributing the generated power on more than three windings, thus further reducing temperature and other problems.
• the charging station may have a mode selector circuit (not shown in Fig. 4a or Fig. 5a) which is configured to receive a mode signal which is indicative whether the electric energy storage requires AC current or DC current.
• the mode selector connects the bridge rectifier (RDi, RD 2 , RD 3 , RD 4 ) to the at least one secondary winding of the n-phase transformer and in AC charging mode disconnects the bridge rectifier from the at least one secondary winding of the n- phase transformer.
• the transformer 8 may still be used for generating a AC charging voltage/current.
• DC/DC converter 4 there are three DC/DC converter 4, each of which powers a charging module.
• the number of DC/DC converter 4 and charging modules may vary, there may be embodiments where the number of DC/DC converter 4 and charging modules is less than three, i.e. one or two. Alternatively in other embodiments the number of DC/DC converter and charging modules could be chosen to be higher than the number of three.
• charging station is used throughout this description to refer to any charger that is suitable for charging at least one electric vehicle.
• charging point is used to indicate that only one electric vehicle can be re-charged at a time, for example in a domestic garage from a charger fixed to the wall of the garage, and the term charging station seems to be used when more than one electric vehicles can be charged simultaneously at one site.
• charging station as used in this description should be not restricted to the number of electric vehicles to be charged. Therefore in this description the term charging stations should be interpreted to embrace charging points.
• the embodiment has been described with a public power grid as a power source. The person skilled in the art will appreciated that the invention is not limited to public power grids, but is also applicable for singular power sources and/or non-public power, such as solar panels, water turbines or wind turbines.

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• 2019
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