WO2023146504A1

WO2023146504A1 - Electric vehicle charging system using mobile, fast and clean energy

Info

Publication number: WO2023146504A1
Application number: PCT/TR2023/050066
Authority: WO
Inventors: Ahmet Ozan CELIK
Original assignee: Eskisehir Teknik Universitesi
Priority date: 2021-01-28
Filing date: 2023-01-27
Publication date: 2023-08-03
Also published as: TR2022001153A2; TR202101311A1; WO2022164414A2; WO2022164414A3; EP4285458A2

Abstract

The invention is an electric vehicle charging system comprising : a roaming electric and/or fossil fuel charger vehicle (1) comprising at least one modular and replaceable battery group (2), multiple foldable and embedded integrated solar panel (5) systems and a controller and a control system having a battery management module (11), at least one DC-AC converter and converter control component, at least one rooftop solar power plant (13) and at least one hydrogen fuel cell, at least one terminal (12) comprising a GPS-based application with a database for storing data, enabling users to establish a connection with the charger vehicle (1), to control and monitor the charging processes, and to make payment for the service.

Description

ELECTRIC VEHICLE CHARGING SYSTEM USING MOBILE , FAST AND

CLEAN ENERGY

Field of the Invention

The invention relates to an electric vehicle charging system, which includes a roaming electric charger vehicle , which is developed for the purpose of on-site fast charging electric vehicles , which feeds itsel f and the replaceable battery groups contained therein from clean energy sources and fuel cells , and which can also be quickly recharged .

Known State of the Art

Rapidly developing technology, population growth and rising globali zation cause the rapid depletion of high-energy and non-renewable energy resources , especially oil products . Vehicles , in particular, have a very high share in terms of energy consumption . Although the movement of vehicles can be driven by electric motors , the use of internal combustion engines is quite common today . The main reasons for this situation are low battery capacity of electric vehicles and limited number and location of charging stations .

The ef ficiency of internal combustion engines is low and their use leads to serious problems for human health and the environment . With the use of these engines , the harmful gas emissions ( especially CO2 emissions ) generated are quite high compared to the amount of fuel consumed . In addition, the decrease in fossil fuel reserves and the increase in demand constitute an economic disadvantage . Due to the aforementioned facts , the automotive industry has been shi fting to the production and use of electric vehicles . Charging electric vehicles is usually carried out via charging units in fixed positions . For charging operations , the location of the charging stations and an application/contact with the operator company must be established, the vehicle must be taken to the charging stations and the battery charging process must be carried out by remaining in that position for a certain period of time . Charging stations are investments that cannot be easily updated and due to their fixed location, they prevent the easy charging o f electric vehicles and prevent the widespread use of electric vehicles as well .

There are documents in the art describing the various systems that have been developed for charging electric vehicles .

The patent document no . US20160023562A1 may be referred as an example for the current state of the art . The aforementioned document deals with a portable charger for charging electric vehicles . The unit of the said document itsel f requires transportation by a vehicle or by a vehicle needs to be charged and fed o f f the grid/another vehicle with combustion engine per se .

Another example of the current state of the art is the patent document No . US 8963481B2 . The aforementioned document features a charging service tool and modular batteries for charging electric vehicles . Combustion engine vehicles are used in the mobile charging units (battery group ) of the said document , the mentioned vehicles can charge with generator support with combustion engine power and the vehicles being a standard commercial vehicle with combustion engine .

Since the combustion engine alternators to be used by the portable charging units , which can be an alternative to the fixed units in the aforementioned documents , do not provide charging conditions in the desired time and compliance , there may be a large additional load on the electricity grids and the vehicles that provide mobility are themselves working with combustion engines , the aforementioned documents do not provide solutions to the problems in the art . In addition, the fast charging conditions and the trans fer of power from the combustion engines di f fer and the battery technologies of the new electric vehicles introduced to the market today provide di f ferent charging conditions . In addition, the transmission of an energy equal to a household consumption of one-week or more into an electric vehicle battery group within a period of 30-45 minutes causes a serious loading on the grid and constitutes a signi ficantly greater amount than the electric energy that can be obtained from combustible engine power of a vehicle to be generated in the same periods .

Another example of the current state of the art is the patent document No . CN107985104A. The aforementioned document features a charging system for charging electric vehicles . It is stated in the document that due to the low battery capacity, low charging li fe and high cost , a solution is found with mobile and permanent batteries for the vehicle of the document . However, the vehicle of the said document is fed of f the grid and in addition, al l resources of the vehicle are exhausted after the charging process . Therefore , the system has to recharge itsel f by moving the vehicle per se . This situation creates a disadvantage in cases where more than one electric vehicle needs to be charged and the charging time is long due to the AC charging of the vehicle . In addition, considering that today' s vehicles have batteries with an energy capacity of 20- 120 kWh, one can understand that it is not possible to feed the said batteries quickly only by relying on solar panels on the vehicle ( 150-400 W x number of panels ) . In addition, the system subj ect to the said document is related to the urgent charging process in case of emergencies and there is no fast charging feature in the system in question . An example of the charging system of the aforementioned patent document no . CN107985104A, the m- charging system in Turkiye can be given as follows : (http : / / tr . ma rmass istance . com/m-sar ) . The aforementioned m-charging system allows for on site charging of vehicles solely in the form of emergency road assistance . There is no advancement in the system that enables electric vehicle drivers to quickly identi fy and communicate with the closest charging vehicle during both regular use and emergency situations . One with ordinary skill in the art recogni zes that this will result in a delay for the charger vehicle to reach the electric vehicle . In addition, persons of ordinary skill in the art may acknowledge that the said charging system lacks the necessary capacity to enable fast charging of vehicles .

Another document that can be referred as an example for the current state o f the art is the patent document no . WO2015160937A1 . This document is related to the installation of a charging kit on commercial ( fossil fuel ) vehicles operating on motorways and highways and the vehicle is not fully in circulation . In addition, the vehicle of the said document does not have the potential to go/reach every vehicle that needs to be charged . It is not possible for tow trucks , which has a trailer starting from 13 . 6 m length, to reach an electric vehicle that needs to be charged in an urban environment and it can only serve as a mobile charging vehicle while its on a break at a speci fic point on a highway . The trailer and tow truck speci fied in the document in question are disadvantageous due to their s i ze even i f they serve only for the electric vehicle charging process and due to the lingering problem of CO2 emission . In addition, the 30- 110 m² solar panel is not suf ficient cons idering the power trans fer and the amount of electrical energy trans ferred for the fast charging of the vehicle .

Another charging system/ charging station similar to the invention of the above-mentioned document no . WO2015160937A1 is described in the useful model document no . TR2020 20573 U4 . When the system described in the aforementioned document is examined in detail , it deals with a charger vehicle that can charge hybrid vehicles at a regular speed . Therefore , the lack of the fast charging option o f the said charger vehicle results in a long time required for charging operations . In addition, the mobile vehicle is not electric . The vehicle ' s batteries are charged from the grid, thereby resulting in a load impact on the grid . Furthermore , the said system does not include developments related to solar panels .

Another document that can be referred as an example for the current state o f the art is the patent document no . US20180264955A1 . The system of the above-mentioned document includes an electric truck and trailer . The said system is unable to provide service for every vehicle in need of a charge located in an urban environment . In addition, it involves transporting the battery group in a trailer pulled by a truck to areas where there may be a high concentration of electric vehicles and leaving them there . As a result , it is evident that the charging system of the document is not completely free to circulate . The battery group has a fixed structure . Furthermore , the document ' s system lacks developments that would allow the user to track and communicate with the charger . Therefore , one can expect that the charger vehicle would not be able to reach the location of the electric vehicle to be charged directly and promptly . Moreover, the aforementioned document allows for providing energy from both renewable sources and the grid . For this reason, the said charging system becomes a system loaded on the grid . In the charging system, only the number o f DC-AC/AC- DC cycles is reduced, saving the energy lost during the conversion, but the load on the grid could not be avoided . The trailer' s solar panels are described in the document , but they are designed exclusively for recharging the vehicle ' s onboard battery . Besides , the said system does not include developments related to solar panels . Additionally, in the document ' s system, the terminal only has a DC charging system . For this reason, it lacks any equipment required for AC energy conversion for the purpose of supplying the grid . The battery group it carries is fixed and cannot be changed .

Consequently, to overcome the aforementioned disadvantages , the need still remains for a charger vehicle and a charging system comprising the same , with the ability to get charged from a clean energy source quickly, to provide fast charge to electric vehicles without loading the grid, which has an on site access to every location, particularly in urban environments .

Detailed Description of the Invention

The invention relates to a solar-powered roaming EV charger vehicle (EV-BEE ) and an electric vehicle charging system comprising the said charger vehicle , engineered to provide on-site fast charging to electric vehicles , which can feed itsel f and replaceable battery groups contained therein, using clean energy sources such as solar power etc . and fuel cells as well as the capability to get recharged quickly . The presence of GPS module in the said charging system customers/users to locate or request the electric charger as needed . An obj ect of the invention is to produce an electric charging vehicle that has the ability to arrive at any location where electric vehicles in need are located, especially in cities , and that can easily reach even the areas where they are parked, and thereby serving for the expansion of electric vehicle utili zation . Therefore , it contributes to the reduction of the external dependence and CO2 emission problems caused by fossil fuels and provides a solution to the range problem of electric vehicles .

Another obj ect of the invention is to charge electric vehicles by using renewable/clean energy sources such as solar energy etc . and thereby minimi zing harmful gas emissions . In addition, the amount of load imposed on the grid for charging electric vehicles can be reduced in this way .

Another obj ect of the invention is to perform fast charging operations of multiple electric vehicles in a short time . Therefore , the present inventors ensure the continuity of the charging process by developing a roaming EV charger vehicle with fast charging feature and comprising modular/replaceable batteries .

Another obj ect of the invention is to solve the range problem of electric vehicles . The solution of the aforementioned problem is provided by the fleet of vehicles circulating within a city and between cities and whose energy is supplied by clean sources .

The invention is an electric vehicle charging system, in its most general form;

- an electric and/or fossil fuel roaming charger vehicle ( 1 ) comprising at least one modular and replaceable battery group (2) for charging an electric vehicle (3) and a controller for management of more than one foldable and embedded integrated solar panel (5) system to recharge the said battery group (2) , the electric vehicle (3) and itself, and a control system having a battery management module (11) ,

- at least one DC-AC converter and converter control element for converting DC energy in the battery group (2) to AC energy,

- at least one rooftop solar power plant (13) and at least one hydrogen fuel cell for charging the battery group (2) , the charger vehicle (1) and the electric vehicle (3) , and

- at least one terminal (12) comprising a GPS-based application with a database for storing data, enabling users to establish a connection with the charger vehicle (1) , to control and monitor the charging processes, and to make payments for the service.

In an embodiment of the invention, the rooftop solar power plant (13) comprises multiple centers, which can be large or small. The size of the rooftop solar power plant varies according to its scope. For example, said rooftop solar system can be positioned on a car parking lot roof.

In an embodiment of the invention, the solar power plant (13) is at least 50 kW for the roof. In an embodiment of the invention, the solar panels (5) located on the charger vehicle (1) are at least 3 kW. This installed power increases for different vehicle types.

In an embodiment of the invention, the hydrogen fuel cell is of an industrial type. Preferably, it is at least 5kW. In an embodiment of the invention, the charger vehicle (1) is an electric vehicle. Preferably, the electric vehicle is an electric minivan, electric van, electric bus, electric truck comprising a trailer suitable for solar panel coating. The charger vehicle (1) can be selected from the group of 2nd, 3rd, 4th and 5th class electric vehicles.

In an embodiment of the invention, the charger vehicle (1) is a hybrid vehicle. Preferably, the electric and fossil fuel bus is an electric/ fuel cell or fossil fuel truck.

In an embodiment of the invention, the charger vehicle (1) is a fossil fuel vehicle. Preferably, the said vehicle is a fossil fuel bus or fossil fuel truck comprising a trailer suitable for solar panel coating. The charger vehicle (1) can be selected from the group of 4th and 5th class fossil fuel vehicles .

In an embodiment of the invention, the battery group (2) is located in the cargo area of the charger vehicle (1) .

In an embodiment of the invention, the terminal (12) is a mobile/ smartphone . Terminal (12) comprises a GPS-based mobile and web application with a database for storing data, enabling users to establish a connection with the charger vehicle (1) , to control and monitor the charging processes, and to make payments for the service.

In an embodiment of the invention, the battery group (2) comprises a lithium-ion battery group. Considering that the charging system of the invention includes a modular battery group (2) , a more effective battery group than the lithium battery group, it can switch to operation with the new battery group . In an embodiment of the invention, there are battery groups of 50 kWh-500 kWh.

In an embodiment of the invention, the battery group (2) comprises an converter.

An embodiment of the invention includes a DC-AC converter, distribution board, and wiring.

In an embodiment of the invention, the solar panels have an area of 5-50 m² or 5-90 m². The said integrated solar panels have a structure on the charger vehicle (1) that can be folded and embedded in the vehicle casing, and have an area that varies according to the vehicle type (urban vehicle, intercity liner vehicle, truck, etc.) to be used as a charger vehicle (1) . The said solar panels (15) have a structure that can be integrated into the vehicle and transported in a way that does not impede the vehicle's movement in traffic when folded, and can operate with all of its functions when unfolded.

In an embodiment of the invention, the charger vehicle (1) comprises a regenerative brake system (14) for charging its own battery and battery group (2) .

In an embodiment of the invention, the charger vehicle (1) comprises a thermal management system. The said thermal management system includes a cooling system. The cooling system is preferably located in the cargo area.

In an embodiment of the invention, there is at least one converter in the electric vehicle (3) and in the solar power plant (13) for charging the electric vehicle (3) via the solar power plant (13) . In an embodiment of the invention, the electric charger (1) carries 50-500 kWh of energy while the cargo is fully loaded.

The electric vehicle charging system of an embodiment of the invention and the charging processes related to said system are shown in Figure-1. Figure-1 shows the following components: lithium-ion or different battery groups (2) , which are the most suitable choice in terms of cost efficiency, energy efficiency, heat performance, weight and cycle criteria, a charger vehicle (1) with a cargo area containing 50kWh-500kWh battery groups (2) and foldable and embeddable solar panels (5) in the vehicle casing, an electric vehicle (3) , a rooftop solar power plant (13) and a smartphone/ terminal (12) comprising a mobile and/or web-based application .

In more detail, the charging processes carried out by the charging system of the invention in Figure 1 comprises the following: charging process (4) of electric vehicle (3) via battery assembly (2) , charging process (6) of the battery group (2) in the cargo area via the collapsible solar energy panels (5) on the electric charger vehicle (1) , charging process (7) of electric vehicle (3) via foldable solar panels (5) located on electric charger vehicle (1) , charging process (8) of the electric charger vehicle (1) via the solar panels (5) on the electric charger vehicle (1) , charging process (9) of the battery group (2) via the roof-type solar power plant (13) and charging process (10) of electric vehicle (3) via roof-type solar power plant (13) .

In addition, the charging operations carried out with the charging system of the invention include the following: charging of an electric vehicle such as an electric scooter etc. from the f oldable/embeddable solar panels (5) on the electric charger vehicle (1) , charging of the battery group (2) in the cargo area from an industrial type fuel cell/hydrogen fuel cell, AC charging for units that may require emergency AC energy, such as a home, hospital, a search and rescue zone via battery assembly (2) .

The electric vehicles (3) charged via the charging system of the invention contain all charging cables and sockets required for the charging process.

The electric charger vehicle (1) in the charging system of the invention includes a controller and a battery management module (11) that enables the application of the said charging processes. At the same time, the control and monitoring of the charging modes can be done by means of a GPS-based smartphone application.

Charging of the battery groups (2) in the cargo compartment of the electric charger vehicle (1) fleet occurs in at least one roof-type solar power plant (13) , and if necessary or where appropriate, the electric charger vehicle (1) uses the solar panels (5) or at least one hydrogen fuel cell on its own platform. A regenerative brake system (14) is also included in the electric charger vehicle and the electric charger vehicle (1) can charge its own battery and/or the battery groups (2) in the cargo area. The electric charger vehicle (1) can also proceed directly with the energy coming from the solar panels (5) instead of its own battery.

In one embodiment of the invention, class 3 vehicles (bus) , class 4 vehicles and class 5 trucks (fault liners or hard case trailers) , including circulating M2 category & class 1 and class A vehicles, can also be converted into a fast charging station and included in the system' s network, using battery, solar panel and converter equipment , while continuing their regular travel operations and transportation services .

By the mobile application terminal ( smartphone ) ( 12 ) in the charging system of the invention, the owners of the electric vehicle ( 3 ) can call the mobile electric vehicle ( 1 ) for charging to their location, follow the charging process of their batteries on the said application and also make payments by the application for the service . In practice , all data can be stored securely . Charging vehicle/vehicles and battery levels can be monitored via a GPS-based system . The same mobile application provides a convenient payment experience .

With the elements such as DC-AC converters , cables , converter control elements , etc . in the charging system of the invention, it is possible to provide energy to the units that need AC and to the AC charging process of electric vehicles .

The charging system of the invention and the electric charger ( 1 ) in the system contain all the necessary components for the AC charging process . The components required for AC charging in more detail comprise the following : thermal management system, 100 V input -> DC/DC 400V output -> Battery management system (BMS ) , 400V output from cargo battery assembly ( 50-500kWh) -> battery management system, (AC charging) BMS->400 V -> DC/AC converter ->230 V AC charging socket -> electric vehicle ( 3 ) and ( DC charging) BMS->400 V -> DC/DC -> 400 V DC charging socket -> electric vehicle ( 3 ) .

One of the most signi ficant advantages of the charging system of the invention is that the electric charger vehicle ( 1 ) in the system has the capacity to refill 80% an electric vehicle within half an hour or less with its storage of 50-500 kWh or more. In addition, the electric charger vehicle (EV-BEE) (1) gets ready for recharging operation with a battery group refilled with 50-500 kWh by replacing with some other battery groups that have been filled in a central unit within an off- grid solar power plant within an hour. Thereby, the continuity of the charging process is ensured.

Another important advantage of the charging system of the invention is that it includes a rooftop solar power plant. The solar power plant (13) , being a rooftop solar power plant and battery exchange stations containing a rooftop solar power plant can be installed in different buildings and parking lots located in and between cities and can be integrated into the mobile charging system. In this case, replaceable battery groups can be charged not only with solar panels, but also with fuel cell and other clean energy sources.

Another important advantage of the charging system of the invention is that the solar panels (5) (5-50 m²) thereon have a foldable structure and can be unfolded during the charging process in a parked position and can increase the surface area 2-4 times, allowing the energy storage process (electric charging vehicle (1) , electric vehicle (3) and battery group (2) ) to be continued. In addition, the solar panels (5) have a structure that can be embedded in the vehicle's casing.

Another advantage of the charging system of the invention is that it includes all the necessary components for AC charging processes. In addition to AC charging electric vehicles with the aforementioned AC charging process feature, the same can provide AC energy supply to units requiring AC energy such as homes, hospitals, etc. Another signi ficant advantage of the charging system of the invention is the feature of fast charging capability .

The charging system of the invention is more advantageous than a fixed station system and investment in that it consists of modular and replaceable units and in that these battery groups ( 2 ) are updated/renewed i f desired . In addition, this clean technology is made widespread and environmental problems are prevented by the fact that the vehicle in circulation is an electric vehicle per se .

The battery groups ( 2 ) , converters , solar panels ( 5 ) in the charging system of the invention can be continuously renewed and updated with their more ef ficient , lighter and more ef fective counterparts depending on technological development .

In summary, with the invention, a charging system has been developed using clean energy sources , which provides DC or AC charging service quickly and can be easily accessed by electric vehicles .

Description of the Figures

Figurel - A View of the Electric Vehicle Charging System of the Invention

Descriptions of Reference Numbers in Figures

1 . Charger vehicle

2 . Battery group

3. Electric vehicle

4 . Charging of electric vehicle ( 3 ) via battery assembly ( 2 )

5 . Solar panel 6. Charging process of the battery group (2) in the cargo area via the collapsible solar energy panels (5) on the charger vehicle (1)

7. Charging of electric vehicle (3) via solar panels (5) located on the charger vehicle (1)

8. Charging the electric charger vehicle (1) via the solar panels (5) on the electric charger vehicle (1)

9. Charging of the battery group (2) via the rooftop solar power plant (13)

10. Charging of electric vehicle (3) via rooftop solar power plant (13)

11. Battery management module

12. Terminal

13. Solar power plant

14. Regenerative braking system

Claims

CLAIMS n electric vehicle charging system comprising: - an electric and/or fossil fuel roaming charger vehicle

(1) comprising at least one modular and replaceable battery group (2) for charging an electric vehicle (3) and a controller for management of more than one foldable and embedded integrated solar panel (5) system to recharge the said battery group (2) , the electric vehicle (3) and itself, and a control system having a battery management module (11) ,

- at least one DC-AC converter and converter control element for converting DC energy in the battery group

(2) to AC energy,

- at least one rooftop solar power plant (13) and at least one hydrogen fuel cell for charging the battery group

(2) , the charger vehicle (1) and the electric vehicle

( 3 ) , and

2. A charging system according to claim 1, wherein the battery group (2) is located in the cargo area of the charger vehicle (1) .

3. A charging system according to claim 1, wherein the battery group (2) comprises a lithium-ion battery group.

4. A charging system according to claim 1 or claim 3, wherein the battery group (2) is 50 kWh-500 kWh.

5. A charging system according to claim 1, wherein the solar power plant (13) is at least 50 kW.

6. A charging system according to claim 1, wherein the solar panels (5) are at least 3 kW.

7. A charging system according to claim 1, wherein the solar panels (5) have an area in the range of 5-50 m².

8. A charging system according to claim 1, wherein the electric charger (1) comprises a regenerative brake system (14) for charging its own battery and battery group ( 2 ) .

9. A charging system according to claim 1, wherein the electric vehicle (3) and the solar power plant (13) comprise at least one converter for charging the electric vehicle (3) from the solar power plant (13) .

10. A charging system according to claim 1, wherein the hydrogen fuel cell is at least 5kW.

11. A charging system according to claim 1, wherein the charging means (1) comprises a thermal management system comprising a cooling system.

12. A charging system according to claim 11, wherein the cooling system is located in the cargo area.

13. A charging system according to claim 1, wherein the terminal (12) is a mobile/ smartphone .

. A charging system according to claim 1, wherein the charger vehicle (1) is an electric pick-up, electric minivan, electric van, electric bus, electric truck with a dorset, electric and fossil fuel bus, electric and fossil fuel semi-trailer or trailer truck, fossil fuel bus or fossil fuel truck with a dorset.