US-12617301-B2 - Bidirectional multi-port DC-DC converter for mobile charging applications

Abstract

This disclosure is directed to mobile electric vehicle charging systems including a storage battery and a controller, coupled to the storage battery. Additionally, the system may include a DC-DC converter module coupled to the controller, having a high voltage interface, an electric vehicle interface, and a storage battery interface. The high voltage interface electrically couples the converter module to a high voltage power source via an AC-DC converter, the storage battery interface electrically couples the converter module to the storage battery, and the electric vehicle interface electrically couples the converter module to an electric vehicle battery. The DC-DC converter is configured to transmit power to and from the high voltage source, the storage battery, an electric vehicle battery in response, at least in part, to a signal from the controller.

Inventors

• Ali Sharida
• Sertac Bayhan
• Haitham Abu-Rub

Assignees

• QATAR FOUNDATION FOR EDUCATION, SCIENCE AND COMMUNITY DEVELOPMENT

Dates

Publication Date

20260505

Application Date

20241107

Claims (20)

1. 1 . A system comprising: an AC-DC converter; a storage battery; a controller, communicatively coupled to the storage battery; and a DC-DC converter module coupled to the controller, the DC-DC converter including a high voltage interface, an electric vehicle interface, and a storage battery interface, wherein the high voltage interface electrically couples the converter module to a high voltage power source, the storage battery interface electrically couples the converter module to the storage battery, and the electric vehicle interface electrically couples the converter module to an electric vehicle battery, and wherein the DC-DC converter is configured to transmit power to and from the high voltage source, the storage battery, an electric vehicle battery in response, at least in part, to a signal from the controller.
2. 2 . The system of claim 1 , wherein, in a first operating mode, the DC-DC converter module is electrically disconnected from the electric vehicle battery and the DC-DC converter module transmits power from the high voltage power source to the storage battery.
3. 3 . The system of claim 2 , wherein the controller causes the first operating mode to be activated when the electric vehicle battery is disconnected from the electric vehicle interface, a state of charge of the storage battery is less than a predetermined threshold state of charge, and the high voltage power source has a sufficient energy supply to charge the storage battery.
4. 4 . The system of claim 1 , wherein, in a second operating mode, the DC-DC converter module is electrically disconnected from the electric vehicle battery and the DC-DC converter module transmits power from the storage battery to the high voltage power source.
5. 5 . The system of claim 4 , wherein the high voltage power source comprises an electrical grid, and the electrical grid repurposes the power from the storage battery.
6. 6 . The system of claim 4 , wherein the controller causes the second operating mode to be activated when the electric vehicle battery is disconnected from the electric vehicle interface, a state of charge of the storage battery is above a predetermined threshold state of charge, and an energy demand on the high voltage power source exceeds an energy supply of the high voltage power source.
7. 7 . The system of claim 1 , wherein, in a third operating mode, the DC-DC converter module is electrically disconnected from the storage battery based at least in part on a signal from the controller and the DC-DC converter module transmits power from the high voltage power source to the electric vehicle battery.
8. 8 . The system of claim 7 , wherein the controller causes the third operating mode to be activated when a state of charge the electric vehicle battery is below a predetermined level of charge and the high voltage power source has a sufficient supply to charge the electric vehicle battery.
9. 9 . The system of claim 1 , wherein, in a fourth operating mode, the DC-DC converter module is electrically disconnected from the storage battery based at least in part on a signal from the controller and the DC-DC converter module transmits power from the electric vehicle battery to the high voltage power source.
10. 10 . The system of claim 9 , wherein the high voltage power source comprises an electrical grid, and the electrical grid repurposes the power from the electric vehicle battery.
11. 11 . The system of claim 9 , wherein the controller causes the fourth operating mode to be activated when a state of charge of the electric vehicle battery is above a predetermined level of charge and an energy demand on the high voltage power source exceeds an energy supply of the high voltage power source.
12. 12 . The system of claim 1 , wherein, in a fifth operating mode, the DC-DC converter module is electrically disconnected from the high voltage power source and the DC-DC converter module transmits power from the storage battery to the electric vehicle battery.
13. 13 . The system of claim 12 , wherein the controller causes the fifth operating mode to be activated when a state of charge of the electric vehicle battery is below a predetermined level of charge and an energy supply through the high voltage interface is insufficient to charge the electric vehicle battery.
14. 14 . The system of claim 12 , wherein the DC-DC converter module is electrically disconnected from the high voltage power supply based at least in part on a signal from the controller.
15. 15 . The system of claim 12 , wherein the DC-DC converter module is electrically disconnected from the high voltage power supply by physical disconnection of the high voltage power supply.
16. 16 . The system of claim 1 , wherein the controller performs periodic checks on a state of the electric vehicle battery, the storage battery, and the high voltage power source.
17. 17 . The system of claim 1 , wherein the controller causes one of a plurality of operating modes to be activated based at least in part on a state of the electric vehicle battery, the storage battery, and the high voltage power source.
18. 18 . A method of managing power transmission in an electric vehicle charger, the method comprising: providing a DC-DC converter module coupled to a controller, the DC-DC converter including a high voltage interface, an electric vehicle interface, and a storage battery interface; measuring a state of charge of an electric vehicle battery electrically coupled to the electric vehicle interface; measuring a state of charge of a storage battery electrically coupled to the storage battery interface; measuring a power level of a high voltage DC bus electrically coupled to the high voltage interface; and determining whether the electric vehicle battery is electrically coupled to the electric vehicle interface.
19. 19 . The method of claim 18 , wherein when it is determined that the electric vehicle battery is electrically coupled to the electric vehicle interface, the method further comprises: while the power level of the high voltage DC bus is determined to be sufficient to charge the electric vehicle battery, charging the electric vehicle battery by power from the high voltage DC bus; and while the power level of the high voltage DC bus is determined to be insufficient to charge the electric vehicle battery: when the state of charge of the storage battery is above a first predetermined threshold state of charge, charging the electric vehicle battery by power from the storage battery.
20. 20 . The method of claim 18 , wherein when it is determined that the electric vehicle battery is not electrically coupled to the electric vehicle interface, the method further comprises: while the power level of the high voltage DC bus is determined to be sufficient to charge the storage battery, charging the storage battery by power from the high voltage DC bus; and while the power level of the high voltage DC bus is determined to be insufficient to charge the storage battery: when the state of charge of the storage battery is determined to be above a second predetermined threshold state of charge, transmitting power from the storage battery to the high voltage DC bus.

Description

PRIORITY CLAIM This application claims the benefit of and priority to U.S. Provisional Patent App. 63/547,740, filed Nov. 8, 2023, the entire disclosure of which is incorporated by reference herein. BACKGROUND Charging stations are generally used to supply electricity from the power grid to the battery of an electric vehicle (EV). Most of the available charging stations are capable of “fast DC charging” by utilizing conventional AC-DC and DC-DC converters to support the conversion of the AC power from grid to DC power at a voltage level receivable by the EV. However, these traditional charging topologies give rise to a plethora of operational issues. For example, as charging stations are generally implemented at a fixed location, charging stations may stress a given area of the power grid in situations where many EVs are pulling power from the grid at the same time, which may result in reliability issues. Additionally, commercial fast DC charging EV stations are generally unidirectional consisting of a controlled rectifier, which includes a number of power switches, which may be vulnerable to faults, which may also result in operational issues. Accordingly, a need exists for a system for EV charging with improved operational reliability. SUMMARY The present disclosure provides a new and innovative system for DC fast charging, including mobile DC fast charging, an EV battery while providing improved electrical reliability. The present disclosure provides a variety of benefits in different applications using the same DC-DC converter module. For example, the present disclosure provides systems, methods, and apparatus which are capable of use to support power grids during peak operation times by drawing unused power from EV batteries and storage batteries integrated into the DC-DC converter module. The system implements logic to determine when it is appropriate for the DC-DC converter module to charge the EV battery or the storage battery, or send power from the EV battery or the storage battery back to the grid to be repurposed. This is capable of vastly increasing generation and demand management of electrical grids, including peak shaving, load shifting, valley filling, and more. The power quality and peak power ratings of electrical grids can be optimized as a result. It is also capable of reducing the cost of charging system designs by reducing the number of required converters. Setup cost, operational cost, and energy cost of charging systems can thereby be substantially reduced. The DC-DC converter module also provides high reliability against faults by providing a redundant current path. This provides the advantage of enhanced fault-tolerant control on component-level and leg-level, and can be extended for module-level and system-level fault-tolerant control. Moreover, each current path will handle half of the power demanded by the load, increasing reliability and expected lifetime of the components and the system as a whole. In a first aspect according to the present disclosure, a system is provided including a storage battery and a controller, coupled to the storage battery. Additionally, the system may include a DC-DC converter module coupled to the controller, having a high voltage interface, an electric vehicle interface, and a storage battery interface. The high voltage interface electrically couples the converter module to a high voltage power source, the storage battery interface electrically couples the converter module to the storage battery, and the electric vehicle interface electrically couples the converter module to an electric vehicle battery. The DC-DC converter is configured to transmit power to and from the high voltage source, the storage battery, an electric vehicle battery in response, at least in part, to a signal from the controller. In a second aspect according to the present disclosure, the system includes a first operating mode, wherein the DC-DC converter module is electrically disconnected from the electric vehicle battery and the DC-DC converter module transmits power from the high voltage power source to the storage battery. The controller is configured to cause the first operating mode to be activated when the electric vehicle battery is disconnected from the electric vehicle interface, a state of charge of the storage battery is less than a predetermined threshold state of charge, and the high voltage power source has a sufficient energy supply to charge the storage battery. In a third aspect according to the present disclosure, the system includes a second operating mode, wherein the DC-DC converter module is electrically disconnected from the electric vehicle battery and the DC-DC converter module transmits power from the storage battery to the high voltage power source. the high voltage power source comprises an electrical grid, and the electrical grid repurposes the power from the storage battery. The controller is configured to cause the second operating mode to be