DESC:FORM 2

THE PATENTS ACT, 1970

(39 of 1970)

&

THE PATENT RULES, 2003

COMPLETE SPECIFICATION

[See Section 10 and Rule 13]

TITLE:

“A UNIVERSAL FAST CHARGING RETRO FITMENT MODULE FOR NON-FAST CHARGE CONTROLLER AREA NETWORK APPLIED BATTERY”

APPLICANT:

TRINITY CLEANTECH PRIVATE LIMITED
A company incorporated under the Indian Companies Act, 1956
having address at
9-1-83 & 84, Amarchand Sharma Complex, S. D. Road, Secunderabad, Hyderabad, Pin Code – 500003, Telangana, India

PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF THE INVENTION
The present invention relates to a retro-fitment fast charging control unit and in particular the present invention relates to a retro-fitment fast charging control unit for a non-fast charge battery in an electric vehicle which is compatible with various types of charging standards.

BACKGROUND OF THE INVENTION
The battery of an electric vehicle is the primary source of energy that powers the motor of electric vehicle. Generally, the battery of electric vehicle is a lithium-ion battery which is rechargeable and offers high energy density, which allows them to store a large amount of energy in a compact and lightweight package.
The battery is charged by using a variety of charging methods such as regular onboard /Off Board charger up to 2 to 3 KVAC, and fast charging. Regular chargers utilizes a standard 110/220-volt household outlet and is able to charge the vehicle at a rate of 0.1C to 0.5C per hour. While fast charging method uses a direct Current (DC) charging station and deliver power at a rate of 10-50 KW of power per hour, depending on the size of vehicle.
In general, the fast charging battery of an electric vehicle typically involves charging the battery to a significant portion of its capacity in a relatively short amount of time and this is achieved by utilizing a high power charging infrastructure such as power outputs of 50kW or higher. In addition to this, non-fast charging battery of the electric vehicle is typically charged by using regular onboard /off board charging infrastructure. The fast charging battery has numerous advantages in comparison with non-fast charging battery.
The conversion of non-fast charging battery to a fast battery is not possible as the ability to fast charge a battery depends on the structure of battery, however the non-fast charging battery is replaced with the fast one to upgrade the vehicle. But, this replacement process consumes a lot of time and resource. To solve this issue, several retro fitment solution were introduced with the development of electric vehicle, however the currently available solutions are not universal and only compatible with one type of charging standard .
US20140028255A1 discloses an electric vehicle-charging station system having charging nodes for networked electric vehicle (EV) and further talks about charging stations having at least two different types of charging guns and the ability for a consumer to receive web-based or consumer-focused information. However, this invention fails to provide a universal retro-fitment solution for non-fast charge controller area network based battery which is compatible with various types of charging protocols.
US7772799B2 discloses about a battery pack including universal battery modules and a master control module. By selecting proper rated universal battery modules and connecting them either in series and/or parallel, a high performance and long life battery pack is assembled that is suitable for high power applications such as electrical vehicles whereby the master control module acts as the battery pack control and interface module. However, this invention fails to provide a universal retro fitment solution for non-fast charge controller area network based battery which is compatible with various types of charging protocols.
US5115182A discloses a battery charging controller which can be integrated within a battery powered device having a rechargeable battery includes a circuit for monitoring the energy consumption of the device from the battery, and for accumulating a measure of the energy consumed since the battery was previously charged. Energy consumption is determined based on the number of device functions being active during predetermined sampling time intervals. When the battery powered device is coupled to an external charging source, the charging of the battery, including the charging rate, is controlled by the energy monitoring circuit within the battery powered device. Rapid charging, slow charging, and discharging of the battery before charging are all readily controlled using an external charging source which requires no circuits for monitoring the battery charging process. However, this invention fails to provide a universal retro-fitment solution for non-fast charge controller area network applied battery.
Hence, fast charging technology has been developed to address the challenges of limited driving range and the time it takes to recharge electric vehicles and energy storage systems. However, not all battery are equipped with fast charging capability and the existing solutions are limited in terms of compatibility with different kinds of fast charging standards.
Therefore, there is a need of a retro-fitment fast charging control unit for non-fast charge controller area network applied battery, which is compatible with various types of charging protocols.

OBJECT OF THE INVENTION
The main object of the present invention is to provide a universal fast charging retro fitment module for non-fast charge controller area network applied battery.
Another object of the present invention is to provide a universal fast charging retro fitment module that is compatible with various types of charging protocols such as DC001, LEVDC, Chademo, and GB/T.
Yet another object of the present invention is to provide a universal fast charging retro fitment module that includes a fast charging controller unit to enable fast charging.
Yet another object of the present invention is to provide a universal fast charging retro fitment module in which the fast charging controller unit generates two isolated power supplies for both sides of controller area network communication.
Still another object of the present invention is to provide a retro-fitment fast charging control unit that significantly reduces the time it takes to recharge the battery, saving more than 50% to 60% of charging time compared to non-fast charging.

SUMMARY OF THE INVENTION
The present invention relates to a retro fitment charging control unit for a non-fast charge battery which is compatible with various types of charging standards that includes a controller unit to significantly reduce the time it takes to recharge the battery, saving more than 50% to 60% of charging time compared to non-fast charging.
In an embodiment, the present invention provides a retro fitment charging control unit for non-fast charge battery is configured for enabling fast charging. The retro-fitment fast charging control unit includes a microcontroller preferably a 32-bit microcontroller having a plurality of controller area network communication controller to communicate with a plurality of fast charging standards such as DC001, LEVDC, Chademo, and GB/T and the microcontroller also monitors a battery charging status and adjusts a charging rate as per requirement.
In another embodiment, the present invention provides the retro-fitment fast charging control unit for non-fast charge battery in which the retro-fitment fast charging control unit operates at a pre-defined power supply that is preferably 12V and generates at least two isolated power supplies for operating two controller area network communications, in which one of the operation monitors a status and condition of said battery of electric vehicle, while the another operation communicates with a fast charger and demands a required power based on said status and condition of said battery. Further, the retro-fitment fast charging control unit operated in a closed loop control system and demands high current depending upon said battery status. In addition to this, the fast charging controller unit reduces the current demand if temperature of said battery is increased beyond a threshold value or the retro-fitment fast charging control unit detects any abnormality in any factor of said battery.
In another embodiment, the present invention provides the retro-fitment fast charging control unit for non-fast charge battery in which a user connects the battery of electric vehicle to a charging station via said retro-fitment charging controller unit. The retro-fitment fast charging control unit communicates with said charging station to determine an appropriate charging standard and adjust the charging rate as per the requirement.
The present invention relates to the retro-fitment fast charging control unit for non-fast charge battery that is compatible with different kinds of fast charging protocols, enables a non-fast charge battery to be retrofitted with fast charging capability, thereby increasing the driving range and reducing the time it takes to recharge the battery. The fast charging controller unit present in the retro-fitment fast charging control unit significantly reduces the time it takes to recharge the battery, saving more than 50% to 60% of charging time compared to non-fast charging, also improves energy storage utilization, allowing for more batteries to be charged in the same space in any given day.
The above objects and advantages of the present invention will become apparent from the hereinafter set forth brief description of the drawings, detailed description of the invention, and claims appended herewith.

BRIEF DESCRIPTION OF THE DRAWING
An understanding of the retro-fitment fast charging control unit for non-fast charge battery of the present invention may be obtained by reference to the following drawings:
Figure 1 is a block diagram of the retro-fitment fast charging control unit for non-fast charge battery in the electric vehicle according to an embodiment of the present invention.
Figure 2 is a flow chart of working of retro-fitment fast charging control unit according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.
Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The present invention relates to a retro-fitment fast charging control unit for non-fast charge battery which is compatible with various types of charging standards and significantly reduce the charging time to recharge the battery, saving more than 50% to 60% of charging time compared to a non-fast charge battery without retro-fitment charging control unit.
In an embodiment, the present invention provides a fast charging system for a non-fast charging battery, comprising, a battery, a charging port, and a fast charging control unit connecting said charging port to said battery wherein, said battery is a non-fast charging battery. The charging port is configured to receive a charging gun from a charging station. The fast charging control unit comprises, a first transceiver unit connected to said charging port, a second transceiver unit connected to said battery, a controller unit configured to adjust charging rate of said battery, a power supply unit, a first isolated power supply unit connected to said first transceiver unit to supply power from said power supply unit, and a second isolated power supply unit connected to said second transceiver unit to supply power from said power supply unit. The fast charging system reduces the time to recharge said battery, by more than 50% to 60% when compared to non-fast charging without fast charging unit.
In an embodiment, the present invention provides a fast charging control unit for a non-fast charging battery, comprising, a first transceiver unit, a second transceiver unit, a power supply unit, a controller unit, a first isolated power supply unit, and a second isolated power supply unit. The controller unit is configured to adjust charging rate of said battery. The first isolated power supply unit is connected to said first transceiver unit to supply power from said power supply unit. The second isolated power supply unit is connected to said second transceiver unit to supply power from said power supply unit. The fast charging control unit reduces the time to recharge said battery, by more than 50% to 60% when compared to non-fast charging without fast charging unit.
In another embodiment, the present invention provides the retro-fitment fast charging control unit for non-fast charge battery in which the fast charging controller unit operates at a pre-defined power supply that is preferably 12V and generates at least two isolated power supplies for operating two communications, in which one of the operation monitors a status of battery of electric vehicle, while the another operation communicates with a fast charger and demands a required power based on said status and condition of said battery. Further, the fast charging controller unit operated in a closed loop control system and demands high current, depending upon said status. In addition to this, the fast charging controller unit reduces the current demand if temperature of said battery is increased beyond a threshold value or the fast charging controller unit detects any abnormality in any factor of said battery.
In another embodiment, the present invention provides the retro-fitment fast charging control unit for non-fast charge battery in which a user connects the battery of electric vehicle to a charging station via said retro-fitment charging control unit. The retro-fitment fast charging control unit communicates with said charging station to determine an appropriate charging standard and adjust the charging rate as per the requirement.
Referring to Figure 1, a block diagram of the retro-fitment fast charging control unit (4) for a non-fast charge battery (2) in the electric vehicle is depicted. The retro-fitment fast charging control unit (4) is installed and configured with said non-fast charge battery (2) for enabling fast charging. The retro-fitment fast charging control unit (4) includes a controller unit (15) preferably a 32-bit microcontroller, at least two transceivers (11), (17), a power supply unit (16) and at least two isolated power supply units (18), and (19). The controller unit (15) operates on the pre-defined power supply (16) that is preferably 12V. The controller unit (15) having a plurality of controller area network communication controllers configured to communicate with a plurality of charging guns/standards such as DC001, LEVDC, GB/T, Chademo and others. The plurality of charging guns/standards are the fast charging connector standards.
The two transceiver units (11), (17) are controller area network communication based transceivers, where the first transceiver unit (11) is connected to a charging port (10) configured to receive charger information signal through a first communication channel (12). The charger information signal includes controller area network identity of the charging connector connected to the charging port (10). Thus, said controller unit (15) identify the charging connector standard based on the received the controller area network identity (CAN ID) of the charging connector, i.e. as the user connects the fast charger (5) to the battery via charging gun (8), the retro-fitment fast charging control unit (4) identifies the CAN ID of the charger connector. For example, in case of LEVDC connector CAN ID starts with digits 500 and 5001, and in case of GB/T or DC001, PGN Parameter Group Number is identified.
The second transceiver unit (17) communicates with a battery management system (BMS) (3) of the non-fast charge battery (2) configured to receive battery information signal via communication channel (13). The battery information signal is related to different parameters of the battery. The different parameters of the battery are state of charge (SOC), voltage demand, current demand, maximum temperature of the battery and battery error information in case of error conditions. The controller unit (15) receives current demand and voltage demand from the battery information signal and sends the voltage and current demand to the fast charger (5).
The retro-fitment fast charging control unit (4) generates at least two isolated power supplies (18), (19) for performing two communication operations, in which one of the operation monitors a status and condition of battery (2) of electric vehicle (1) with the help of Battery Management System (3) (BMS), while the another operation communicates with a fast charger (5) and adjust charging rate based power based on said status and condition of said battery (2). Further, the retro-fitment fast charging control unit (4) operated in a closed loop control system and demands high current, depending upon said status i.e. fast charging is provided when temperature of said battery temperature of said battery (2) is up to 50°C. In addition to this, the fast charging controller unit (4) reduces the current demand if temperature of said battery (2) is increased beyond a threshold value or the retro-fitment fast charging control unit (4) detects any abnormality in any factor of said battery (2) with the help of communication channel (13), i.e. if temperature of said battery (2) increases beyond 50°C temperature then charging is terminated.
The battery (2) is provided with temperature sensors preferably negative temperature coefficient (NTC) based temperature sensors configured to sense temperature of said battery (2) and being monitored by the battery management unit (BMS) (3). The BMS transmits the temperature information via controller area network communication channel (13) in predefined time intervals. The predefined time interval ranges from 100 milli seconds to 10 seconds. Further, the temperature information is sent to the controller unit (15) that processes the information and decodes maximum battery temperature value from received data. Table 1 illustrates controller area network information decoding structure of retro-fitment fast charging control unit (4):

Table 1: Controller area network information decoding structure of retro-fitment charging control unit
The retro-fitment fast charging control unit (4) for non-fast charge battery (2) in which a user connects the battery of electric vehicle (1) to a charging station via said retro-fitment control unit. The charging station (200) has a fast charger (5), that further includes charging guns/standards (6), (7) and (8). Any of the charging gun is then connected to a charging port (10) of the electric vehicle (1). The charging port (10) is further connected to a switch (9) to control the power supply to the battery (2). The controller unit (15) present in the retro-fitment fast charging control unit communicates with said charging station to determine an appropriate charging connector standard and adjusts the charging rate as per the requirement.
Referring to Figure 2, a flow chart of working of retro-fitment fast charging control unit (4) is depicted. The retro-fitment fast charging control unit (4) checks whether said fast charger (5) is connected or not, and if connected then the retro-fitment fast charging control unit (4) is switched on and its controller unit (15) is powered by 12V power supply (16). The two isolated power units (18), (19) receive power from power supply unit (16). The fast charger (5) receives a hardware acknowledgement signal or vehicle detection signal from retro-fitment fast charging control unit (4). Further, the fast charger (5) will detect the vehicle and sends an immobilization signal to the vehicle to prevent it from moving while charging.
The controller unit (15) of retro-fitment fast charging control unit (4) initiate digital communication with the fast charger (5) and vehicle (1) through communication channels (12), (13), and communication between vehicle charging port and charging gun using CAN lines. The controller unit (15) identifies a charger standard and checks if there is requirement of charging, if yes then the retro-fitment fast charging control unit (4) determines voltage and current demand and closes the switch (10). The voltage and current demand is based on parameters received from BMS unit i.e. state of charge (SOC), voltage demand, current demand, maximum temperature of the battery and battery error information in case of error conditions. Further, the control unit (15) transmits the determined voltage and current demand to said fast charger (5). The fast charger (5) charges the battery based on the received voltage and current demand. Simultaneously, the controller unit (15) monitors the charging level and health status of said battery (2) while charging and if there is no error, charging is maintained. Once the charging is completed then it opens the switch and the whole process terminates. However, in case any error is detected then the process gets terminated.
In an embodiment, the charging controller unit (15) initiates charging by fast charger (5) if predefined conditions are fulfilled, the predefined conditions are as follows:
a) there is no error from fast charger,
b) there is no error from BMS unit,
c) temperature is below threshold temperature (50° C),
d) battery state of charge is below maximum threshold, here it is set for 80% SOC,
e) all communication are proper.
The communication will continue but charging will terminate in case any below conditions met:
a. any error from BMS or fast charger,
b. if battery temperature is above 50 degree C,
c. if battery charging completed,
d. charging gun disconnected from the vehicle charging port.
In an embodiment, the retro-fitment charging controller unit (4) maintains the voltage and current demand received from BMS. Further, the current demand is dynamically calculated every 500milisecond based on battery condition throughout the charging process and new voltage and current demand is calculated and sent to the fast charger. For example, if battery condition is good then charging control unit (4) demand high current and if the battery temperature increases then charging control unit (4) reduces current demand. Thus, the retro-fitment charging controller unit (4) adjusting the charging rate of said battery (2).
The present invention relates to the retro-fitment fast charging control unit (1) for non-fast charge battery (2) that is compatible with different kinds of fast charging guns/standards (6), (7), (8), and enables a non-fast charge battery to be retrofitted with fast charging capability, thereby increasing the driving range and reducing the time it takes to recharge the battery (1). The retro-fitment fast charging control unit (4) present in the retro-fitment fast charging control unit significantly reduces the time it takes to recharge the battery, saving more than 50% to 60% of charging time compared to non-fast charging, also improves energy storage utilization, allowing for more batteries to be charged in the same space in any given day.
Therefore, the present invention provides a retro-fitment fast charging control unit for non-fast charge battery in the electric vehicle which significantly improves the efficiency, performance, and usability of non-fast charge batteries, thereby promoting the adoption of clean energy technologies and reducing the reliance on fossil fuels.
Many modifications and other embodiments of the invention set forth herein will readily occur to one skilled in the art to which the invention pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
,CLAIMS:CLAIMS

We claim:
1. A fast charging system (100) for a non-fast charging battery (2), comprising:
a battery (2);
a charging port (10); and
a fast charging control unit (4) connecting said charging port (10) to said battery (2);
wherein,
said battery (2) is a non-fast charging battery;
said charging port (10) is configured to receive a charging gun from a charging station (5);
said fast charging control unit (4) comprises:
a first transceiver unit (11) connected to said charging port (10);
a second transceiver unit (17) connected to said battery (2);
a controller unit (15) configured to adjust charging rate of said battery (2);
a power supply unit (16);
a first isolated power supply unit (19) connected to said first transceiver unit (11) to supply power from said power supply unit (16); and
a second isolated power supply unit (18) connected to said second transceiver unit (17) to supply power from said power supply unit (16); and
said fast charging system (100) reduces the time to recharge said battery (2), by more than 50% to 60% when compared to non-fast charging battery.
2. The fast charging system (100) as claimed in claim 1, wherein said controller unit (15) monitors charging level and health status of the battery during charging process.
3. The fast charging system (100) as claimed in claim 1, wherein said fast charging unit (4) is compatible with various charging guns/standards such as Direct Current charging standard (DC001), Low-Speed Electric Vehicle Direct Current charging standard (LEVDC), Chademo, Guobiao/T (GB/T) and others.
4. The fast charging system (100) as claimed in claim 1, wherein said controller unit (15) is configured to receive controller area network identity of said charging gun.
5. The fast charging system (100) as claimed in claim 1, wherein said battery (2) is a non-fast charge controller area network battery.
6. The fast charging system (100) as claimed in claim 1, wherein said fast charging control unit (4) is enabled to be retro fitted with said battery (2) making said battery (2) compatible with a fast charger (5).
7. The fast charging system (100) as claimed in claim 1, wherein said fast charging unit (4) terminates charging process upon completion of charging of said battery without errors, and terminates and reports errors if any abnormalities are detected during the charging process.
8. A fast charging control unit (4) for a non-fast charging battery (2), comprising:
a first transceiver unit (11);
a second transceiver unit (17);
a power supply unit (16);
a controller unit (15);
a first isolated power supply unit (19); and
a second isolated power supply unit (18);
wherein,
said controller unit (15) configured to adjust charging rate of said battery (2);
said first isolated power supply unit (19) being connected to said first transceiver unit (11) to supply power from said power supply unit (16); and
said second isolated power supply unit (18) being connected to said second transceiver unit (17) to supply power from said power supply unit (16); and
said fast charging control unit (4) reduces the time to recharge said battery (2), by more than 50% to 60% when compared to non-fast charging battery.
9. The fast charging control unit (4) as claimed in claim 8, wherein said controller unit (15) monitors the charging level and health status of the battery during charging process.
10. The fast charging control unit (4) as claimed in claim 8, wherein said controller unit (15) is configured with multiple controller area network controllers to communicate with various charging guns/standards such as Direct Current charging standard (DC001), Low-Speed Electric Vehicle Direct Current charging standard (LEVDC), Chademo, Guobiao/T (GB/T) and others.

11. The fast charging control unit (4) as claimed in claim 8, wherein said controller unit (15) is configured to receive controller area network identity of a charging gun connected to said battery (2).
12. The fast charging control unit (4) as claimed in claim 8, wherein said battery (2) is a non-fast charge controller area network battery.
13. The fast charging control unit (4) as claimed in claim 8, wherein said fast charging control unit (4) is enabled to be retro fitted with said battery (2) making said battery (2) compatible with a fast charger (5).
14. The fast charging control unit (4) as claimed in claim 8, wherein said control unit (15) terminates charging process upon completion of charging of said battery without errors, and terminates and reports errors if any abnormalities are detected during the charging process.