Description:BATTERY CHARGING SYSTEM FOR CHARGING SWAPPABLE BATTERIES OF ELECTRIC VEHICLES

Field of the Invention
[0001] The present disclosure generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.

Background
[0002] The description in the Background section includes general information related to the field of the present application. The background is only meant to provide context to a reader in understanding the present invention. It is neither to be taken as an admission that any of the provided information relates to prior art for the presently claimed invention nor that any publication explicitly or implicitly referenced within this section relates to prior art. The background section is merely meant to be illustrative rather than exhaustive and is primarily intended to identify problems associated with the present state of the art.
[0003] Electric vehicles (EVs) rely on efficient battery management systems to optimize performance and extend operational capabilities. Generally, multiple solutions are known for managing the charging of swappable batteries in EVs. One such well-known system involves using individual docking units that can charge batteries directly from a power supply grid. Such systems focus on providing a consistent charge to each battery, ensuring that the EVs can be rapidly serviced and returned to use.
[0004] Usually, another commonly employed technique involves advanced monitoring of the state of charge (SoC) of each battery. Conventionally, systems incorporating SoC monitoring are capable of assessing the precise energy levels of batteries, enabling targeted charging that can prolong battery life and reduce wear. However, these systems often depend heavily on a continuous power supply from the grid, which can be a critical drawback during power outages or when grid electricity prices are high.
[0005] Problems associated with the aforesaid systems include their inability to adapt to external power supply issues such as grid failures or fluctuating energy costs. Additionally, while individual SoC monitoring provides valuable data, many systems do not utilize such data to optimize the distribution of charge between batteries under varying grid conditions.
[0006] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for efficiently managing the charging of swappable batteries in electric vehicles.
Summary
[0007] The following Summary section provides only a brief introduction to the various embodiments of the present invention. It is to be understood that the following paragraphs are neither meant to constitute a complete and thorough description of the claimed subject matter nor is it intended to define the technical features or the scope of the claimed subject matter. Thus, the description in the Summary section is neither intended to identify only the essential features of the present invention nor limit the scope of the claimed subject matter in any manner.
[0008] The present invention generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.
[0009] In an aspect, the present disclosure provides a battery charging system for charging swappable batteries of electric vehicles. The system comprises multiple docking units, wherein each docking unit receives a swappable battery and determines a state of charge (SoC) of the swappable battery received within the corresponding docking unit. The system comprises a control arrangement connected to each docking unit, wherein the control arrangement enables supply of electric current from a power supply grid to each swappable battery received within the multiple docking units to charge the corresponding swappable battery and wherein the control arrangement determines loss of supply of electric current from the power supply grid; identifies a first set of the swappable batteries having the SoC lower than a pre-set threshold; a second set of the swappable batteries having the SoC higher than the pre-set threshold, wherein the pre-set threshold is less than 100% SoC of the swappable batteries of the second set; and causes supply of electric current from the first set of swappable batteries to the second set of swappable batteries to enable charging of each swappable battery of the second set to charge close to maximum (i.e., 100% SoC).
[00010] In an embodiment, the control arrangement disconnects the supply of electric current from the power supply grid to each swappable battery received within the multiple docking units based on an increase in electric current tariff more than a tariff limit and wherein the control arrangement causes the supply of electric current from the first set of swappable batteries to the second set of swappable batteries.
[00011] In another embodiment, each docking unit comprises a mechanical relay to disconnect the supply of electric current between the power supply grid and each swappable battery received within the multiple docking units and wherein the control arrangement is connected to each mechanical relay to cause the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid.
[00012] In yet another embodiment, the control arrangement controls each mechanical relay to enable the supply of electric current from the first set to the second set.
[00013] In still another embodiment, each docking unit comprises a bidirectional converter to manage the supply of electric current from the first set to the second set.
[00014] In another embodiment, the bidirectional converter adjusts voltage levels between the first set and the second set.
[00015] In yet another embodiment, each docking unit comprises a sensor to determine the SoC of the swappable battery received within the corresponding docking unit and wherein each sensor is connected to the control arrangement.
[00016] In still another embodiment, each docking unit comprises an actuator to physically disconnect an electrical connection between the power supply grid and the corresponding docking unit; and physically connect the first set and the second set.
[00017] In another embodiment, each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit.
[00018] In yet another embodiment, the system comprises a temperature sensor within each docking unit to monitor a temperature of the corresponding swappable battery received therein and wherein the control arrangement adjusts the supply of electric current to the corresponding swappable battery based on the monitored temperature.
[00019] In still another embodiment, the system comprises a cooling arrangement connected to the control arrangement and wherein the control arrangement controls the cooling arrangement to manage the monitored temperature of each swappable battery to preventing overheating.
[00020] In another embodiment, the battery charging system comprises a central power storage component and wherein the electric current is supplied from the first set to the central power storage component; and central power storage component to the second set.
[00021] The various objects, features, and advantages of the claimed invention will become clear when reading the following Detailed Description along with the Drawings.
Brief Description of the Drawings
[00022] The following Brief Description of Drawings section will be better understood when read in conjunction with the appended drawings. Although exemplary embodiments of the present invention are illustrated in the drawings, the embodiments are not limited to the specific features shown in the drawings. The drawings illustrate simplified views of the claimed invention and are therefore, not made to scale. Identical numbers in the drawings indicate like elements in the drawings.
[00023] The embodiments of the present invention will now be briefly described by way of example only with reference to the drawings in which:
[00024] FIG. 1 shows a schematic illustration of a battery charging system for charging swappable batteries of electric vehicles, in accordance with an embodiment of the present disclosure.
[00025] Fig. 2 illustrates an exemplary flow diagram about operational procedure of a charging system for swappable batteries used in electric vehicles, in accordance with embodiment of present disclosure.
[00026] Fig. 3 shows a flow diagram to present the operational procedure of a battery charging system for electric vehicles, particularly focusing on how charging station adapts to various power supply conditions to maintain efficient charging, in accordance with an embodiment of the present disclosure.
Detailed Description
[00027] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any single embodiment. The scope of the invention encompasses without limitation numerous alternatives, modifications and combinations.
[00028] It shall be noted that as used within the current section as well as in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Further, the use of words such as “first”, “second”, “third” and the like does not represent any particular order. Such words have been merely employed to distinguish one individual component from another. Moreover, “each” refers to each member of a set or each member of a subset of a set.
[00029] An arrangement of two or more components, unless stated specifically, can be done without limitation in any manner relative to a three-dimensional coordinate system. Thus, a second component arranged underneath a first component may also be taken to mean that the first component is arranged underneath the second component.
[00030] The phrase “configured to” as used through the Detailed Description as well as the appended Claims is to be taken to mean that the particular component that is configured to perform a specific action is specially conceived, designed and subsequently manufactured to enable the particular component to be employed for conveniently performing the specific action. However, this should not be taken to mean that the particular component is only capable of performing one specific action that the particular component is configured to do. It may perform a variety of different actions in addition to the specific action that the particular component has been configured to do.
[00031] The phrase “operably coupled” as used throughout the Detailed Description as well as the appended Claims is to be understood to refer to a coupling between two or more components that such an action performed by or on a first of the components is transferrable as an equivalent action of or on a second of the component that is operably coupled to the first component. It will be appreciated that more than two components may be operably coupled to each other.
[00032] Terms such as “slidably”, “pivotally”, “rotatably” and the like have been employed throughout the Detailed Description as well as the appended Claims to refer to coupling between two or more components such that a first component can move (such as, slide, pivot or rotate) with respect to a second component that is movably coupled to the first component without completely detaching from the first component. It will be appreciated that more than two components may be operably coupled to each other.
[00033] It will be appreciated that various components of the system may be permanently or temporarily (such as, detachably) coupled to each other using various permanent or temporary means, including but not limited to, welding the components together, using screws, nuts, bolts and the like to join the components together, attaching the components using magnets and the like. Such details are commonly available in the art and have therefore been omitted throughout the Detailed Description and the appended Claims for the sake of conciseness.
[00034] It will also be appreciated that modifications, additions, or omissions may be made to the systems and apparatuses described hereinafter without departing from the scope of the Claims. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components.
[00035] The present invention generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.
[00036] Referring to FIG. 1, there is shown a schematic illustration of a battery charging system (100) for charging swappable batteries (102) of electric vehicles, in accordance with an embodiment of the present disclosure. The system (100) comprises multiple docking units (104). Each docking unit (104) receives a swappable battery (102). Further, each docking unit (104) determines a state of charge (SoC) of the swappable battery (102) received within the corresponding docking unit (104). Each docking unit (104) serves as a receptacle for a swappable battery (102), providing mechanical support and electrical connections necessary for charging. The docking units (104) are equipped with sensors and electronic circuits to assess the SoC of each swappable battery (102), thereby enabling individual monitoring and management of the charging process according to requirements of each swappable battery (102). Optionally, each docking unit (104) can be implemented with a user interface to display the charging status and SoC directly at the docking unit (104). Thus, the docking units (104) enable the physical accommodation of the swappable batteries (102) therein while also ensuring that the SoC is accurately measured, thereby, maintaining battery health and extending the lifespan of the swappable batteries (102) by preventing overcharging.
[00037] The system (100) further comprises a control arrangement (106) connected to each docking unit (104). The control arrangement (106) enables supply of electric current from a power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) to charge the corresponding swappable battery (102). The control arrangement (106) is central to managing the operational aspects of the system (100) as the control arrangement (106) controls the flow of electric current from the power supply grid (108) to the swappable batteries (102) based on the SoC data received from the docking units (104). The power supply grid (108) provides the necessary electrical current for charging the swappable batteries (102). The power supply grid (108) is connected to the control arrangement (106). The control arrangement (106) draws electric current from a power supply grid (108) and distributes the electric current among the swappable batteries (102) received into the multiple docking units (104), thereby enabling the charging of each swappable battery (102) according to individual charging requirements and current SoC thereof. Consequently, the control arrangement (106) optimizes the charging process for efficiency and effectiveness. Further, the control arrangement (106) is adapted to monitor the continuity of electric current supply from the power supply grid (108), ensuring that operation of the system (100) is seamless and uninterrupted. Optionally, the control arrangement (106) is connected to each docking unit (104) using wired or wireless communication methods such as Wi-Fi, Bluetooth, or ZigBee to facilitate real-time data exchange and system management.
[00038] Further, the control arrangement (106) determines loss of supply of electric current from the power supply grid (108). In response, the control arrangement (106) identifies a first set of the swappable batteries (102) having the SoC lower than a pre-set threshold and a second set of the swappable batteries (102) having the SoC higher than the pre-set threshold, such that the pre-set threshold is less than 100% SoC of the swappable batteries (102) of the second set. Thereafter, the control arrangement (106) causes supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102) to enable the SoC of each swappable battery (102) of the second set to charge to 100% SoC. In the event of a power outage or reduction in power supply from the grid (108), the control arrangement (106) manages the transfer of electric current between batteries (102) from the first set with lower SoC to those in the second set with higher SoC, ensuring optimal battery (102) usage and efficiency. The control arrangement (106) is capable of identifying two distinct sets of swappable batteries (102), such as the first set with an SoC lower than a pre-set threshold (e.g., 30%, 40%, 50%, 55% etc.) and the second set with an SoC higher than the same threshold. Such a categorization allows the control arrangement (106) to manage the available resources effectively by initiating the transfer of electric current from the first set of swappable batteries (102) to the second set. The transfer is facilitated to enable each swappable battery (102) in the second set to reach a full charge, or 100% SoC. The ability to redistribute electric current in the aforesaid manner significantly enhances efficiency of charging system (100) against power disruptions, ensuring that the most charged batteries (102) reach full capacity, thereby maximizing the readiness and utility of the entire fleet of swappable batteries (102). Optionally, the control arrangement (106) may receive advance notification of upcoming power outages from municipality or government servers. In response, the control arrangement (106) swiftly initiates a protocol to maintain charging operations by reallocating electric current from batteries (102) in the first set with lower SoC to those in the second set with higher SoC, thus ensuring continuous operation without interruption. For example, such an operation of the system (100) enables the control arrangement (106) to proactively redistribute electric current among the swappable batteries (102), thereby maintaining uninterrupted charging operations and preventing potential disruptions in electric vehicle usage due to uncharged batteries.
[00039] The pre-set threshold for the SoC can be dynamically determined by the control arrangement (106) based on several factors that ensure the efficient operation of the system, particularly during interruptions in power supply from the grid (108). Consider a scenario involving charging system (100) with 10 docking units (104), each configured to accommodate a swappable battery (102) for electric vehicles. Out of 10, let's assume 7 docking units (104) contain batteries (102) with varied SoCs. Upon detection disruption in the power supply from the grid (108), the control arrangement (106) analyses the SoC of each battery (102) currently in the docking units (104). Based on analysis, the control arrangement (106) computes an average SoC (i.e., pre-set threshold) or another statistical measure (median, mode, etc.) that best represents the overall energy availability within the system. For instance, if the SoCs are spread between 20% to 90%, the control arrangement might set pre-set threshold at 50% to effectively divide the batteries (102) into two operational groups as first set of batteries (102) with SoC less than 50% (lower energy reserve) and second set of batteries (102) with SoC greater than 50% (higher energy reserve). For dynamic determination of pre-set threshold, control arrangement (106) utilizes several factors such as statistical distribution of charge levels of each battery (102), health of each battery (102), charge/discharge cycles of each battery (102), voltage level of each battery (102), energy density or capacity of each battery (102). For instance, the statistical distribution of battery charge levels involves an aggregate assessment of SoC across all batteries (102) in the station. Suppose the range of SoC varies from 20% to 90% among the batteries (102). By calculating the median or mean, the control arrangement (106) can identify 50% SoC as pre-set threshold. The statistical approach enables that batteries (102) are categorized effectively, maintaining a balance between those needing more charge and those ready to discharge or support the system (100) during high-demand periods. The control arrangement (106) For battery health or SOH of current operational capacity of each battery (102) relative to original specifications thereof. For example, battery (102) that originally held 100 ampere-hours might now hold only 70 ampere-hours due to degradation over time. If the threshold for optimal performance is set at 80 ampere-hours, such battery (102) would fall below the threshold and thereby categorized in first category. Furthermore, charge/discharge cycles each battery (102) also be considered by control arrangement (106). Batteries (102) that have undergone a significant number of cycles, say over 1000 cycles, are likely to exhibit reduced efficiency. For instance, battery (102) designed to withstand 1500 cycles might start showing considerable efficiency loss at cycle 1000. By considering charge/discharge cycle, the control arrangement (106) can categorize such batteries (102) as having lower energy reserves (i.e., first category) to prevent overuse thereof in critical conditions. Furthermore, voltage levels of each battery (102) can be used by control arrangement (106) to determine operational readiness of each battery (102). The battery (102) that consistently shows a voltage level below nominal range thereof, perhaps due to internal resistance or age-related degradation, would be categorized under the lower reserve. For example, if a nominal voltage is 12 volts but a particular battery (102) frequently drops to 10 volts, which indicates instability or reduced capacity, results in categorization into the lower reserve set. The energy density measures the amount of energy battery (102) can store relative to size or weight thereof, directly affecting utility and performance. The battery (102) with high energy density can deliver more power without requiring frequent recharges, ideal for inclusion in the higher energy reserve category, which can be used in EV to provide higher range. Conversely, batteries (102) with lower energy density, which might deliver sufficient power but require more frequent charging and larger physical space, are better suited for the lower energy reserve category. For instance, if the average energy density in the station's battery (102) inventory is 200 watt-hours but several batteries (102) measure only 150 watt-hours, such battery (102) would be categorized as lower energy reserves due to their less efficient energy storage capacity.
[00040] In an embodiment, the control arrangement (106) enables charging process by selecting and preparing batteries (102). Consider a station where batteries (102) vary significantly in their state of charge (SoC), health, and other parameters. To initiate fast charging, the control arrangement (106) can first identify one battery (102) from second set to receive electrical energy from the each of first set of batteries (102) for rapid charge of selected battery (102). Selection of battery (102) from second set can be based on critical requirement, pre-booking status, energy storage capacity, maximum charging current handling capability and the like. Once the battery (102) is selected, control arrangement (106) enables transfer of electrical energy from first set of batteries (102) to the selected batteries (102) of second set. Upon full complete charging, control arrangement (106) selects another battery (102) from second set. This process is continued till all batteries (102) are charged either fully or greater than pre-defined level. The one-by-one charging of batteries (102) can enable that swapping station effectively manages resources during grid interruptions, maintaining supply of maximum number of charged batteries (102) for electric vehicle operations.
[00041] The battery charging system (100) significantly enhances the efficiency of charging operations for swappable batteries of electric vehicles by allowing individualized charging management based on real-time SoC evaluations. The presence of multiple docking units (104) enables simultaneous charging of multiple swappable batteries (102) without affecting the charging of any other swappable battery (102), which is crucial in high-demand scenarios such as electric vehicle charging stations. Additionally, the adaptive power management capabilities of the control arrangement (106) ensure optimal power utilization, reducing waste and improving the overall energy efficiency of the system. The incorporation of intelligent and adaptive charging strategies not only improves the operational efficiency of the charging system (100) but also contributes to the overall sustainability of electric vehicle operations. It will be appreciated that by optimizing the usage of electric power and reducing dependency on constant power supply, the system (100) enhances the energy efficiency and reliability of electric vehicle charging infrastructure. Further, the comprehensive approach to managing the charging of swappable batteries in electric vehicles ensures that the battery charging system (100) remains effective under various operating conditions, thus enhancing the reliability and efficiency of electric vehicle infrastructures. Optionally, the docking units (104) incorporate solar panels on surfaces thereof, enabling the docking units (104) to harness solar energy to supplement the charging of the swappable batteries (102). Consequently, the incorporation of the solar panels makes the system (100) more sustainable while also allowing the system (100) to function in remote areas without reliable access to power supply from power supply grids (108).
[00042] In an embodiment, the control arrangement (106) monitors a present electric tariff (e.g., ? 4/kWh to ? 6/kWh) or receives data related present electric tariff from grid management server or system administrator or operator. The control arrangement (106) disconnects the supply of electric current from the power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) based on monitored or received present tariff. For instance, if the present electric tariff (e.g., ? 10/kWh) is higher than a predetermined tariff (e.g., ? 8/kWh). Subsequently, the control arrangement (106) causes the supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102). The control arrangement (106) is associated with the capability of disconnecting the supply of electric current from the power supply grid (108) to each swappable battery (102) in response to an increase in the electric current tariff exceeding a predetermined limit. Consequently, the control arrangement (106) enables cost-efficiency, allowing the system (100) to operate economically by leveraging lower-cost electric power during off-peak hours and reducing consumption during peak tariff periods. Subsequently, the control arrangement (106) manages the energy resources by facilitating the supply of electric current from the first set of swappable batteries (102), which have lower SoC, to the second set with higher SoC. Such an operation ensures optimal charge management of battery (102) while also enhancing the economic operation of the system (100) by utilizing stored energy in a strategic manner, thus minimizing the impact of high energy costs. Optionally, such a dynamic tariff response capability can be integrated with a real-time energy pricing feed from utility providers, allowing the system (100) to automatically adjust operation based on current energy prices, further optimizing energy costs and efficiency. Thus, during a peak tariff period, the control arrangement (106) detects an increase in energy costs through connection thereof to real-time utility pricing data. The control arrangement (106) responds by disconnecting the electric current supply from the power supply grid (108) and simultaneously, initiates the transfer of stored electric current from the swappable batteries (102) in the first set with lower SoC to the swappable batteries (102) in the second set with higher SoC. Such a strategic management maintains the charging operation without reliance on the expensive power from grid (108) while also optimizing the energy usage of the system (100) by drawing on cheaper stored energy, thereby enhancing the cost-efficiency of the operation. Optionally, the control arrangement (106) employs machine learning algorithms to predict patterns in electricity tariff changes, thus, allowing the system (100) to anticipate cost spikes and adjust charging strategy proactively, further optimizing energy costs.
[00043] In another embodiment, each docking unit (104) comprises a mechanical relay to disconnect the supply of electric current between the power supply grid (108) and each swappable battery (102) received within the multiple docking units (104). The control arrangement (106) is connected to each mechanical relay to manage (e.g., ON or OFF) the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid (108). The inclusion of mechanical relays enhances the reliability and safety of the system (100) by providing a robust means of physically isolating electrical circuits, thus preventing potential electrical faults and improving the overall resilience of the system (100). Such a setup allows for an immediate response to power disruptions, ensuring that the charging process can continue seamlessly without relying solely on the power supply grid (108). Optionally, each mechanical relay in the docking units (104) is be equipped with sensors that detect the physical condition of the relay, such as wear or damage, alerting the system (100) to perform maintenance or replacement pre-emptively, thus avoiding potential failures.
[00044] In yet another embodiment, the control arrangement (106) controls each mechanical relay to enable the supply of electric current from the first set to the second set. The control arrangement (106) actively controls each mechanical relay to enable the redirection of electric current from the first set of swappable batteries (102) with lower SoC to the second set of swappable batteries (102) with higher SoC, effectively balancing the charge levels of batteries (102) across the system (100). Such an operation ensures that all swappable batteries (102) reach optimal charge levels efficiently, enhancing the readiness of the swappable batteries (102) for use in electric vehicles. The capability to manage such relays by the control arrangement (106) precisely allows the system (100) to maintain continuous operation and extend the operational lifespan of the swappable batteries (102) by preventing scenarios of deep discharge or overcharge, thus maximizing the utility and efficiency of the swappable batteries (102). Optionally, the system (100) employs solid-state relays for faster switching speeds and reduced maintenance requirements, thereby enhancing the reliability and speed of switching between power sources.
[00045] In still another embodiment, each docking unit (104) comprises a bidirectional converter to manage the supply of electric current from the first set to the second set. The bidirectional converter enables the efficient charging of the swappable batteries (102) from the power supply grid (108) while also facilitating the transfer of electric current from the first set of swappable batteries (102) with lower SoC to the second set with higher SoC. The bidirectional converter further supports both the intake of electric current from the power supply grid (108) and the redistribution among the swappable batteries (102), ensuring a continuous and efficient charge cycle. Such a capability significantly enhances the adaptability of the system (100) to varying power co

converter shifts to redistribute electricity from the first set of swappable batteries (102) with lower SoC to the second set with higher SoC, thus ensuring a balanced and continuous charging process. Optionally, the bidirectional converters are designed to work with different types of energy storage systems, such as supercapacitors, allowing for rapid energy transfer capabilities and supporting applications requiring quick bursts of energy.
[00046] In an embodiment, the bidirectional converter adjusts voltage levels between the first set and the second set. Such a function of voltage management is critical in managing the differences in voltage requirements between the different sets of swappable batteries (102), ensuring that the transfer of electric current does not lead to overvoltage or undervoltage conditions, which could damage the swappable batteries (102). Further, by adjusting voltage levels appropriately, the bidirectional converter ensures that each swappable battery (102) is charged in the most efficient and safe manner possible, thereby maximizing the lifespan and performance of the swappable batteries (102). The voltage adjustment capability also allows for a more flexible energy distribution strategy, accommodating various battery technologies and specifications within the system (100). During operation, if a significant variance in the voltage requirements between the first and second sets of swappable batteries (102) is determined due to differing charge levels or battery technologies, the bidirectional converter adjusts the voltage levels during the transfer of power from the first set to the second set, thus ensuring that all swappable batteries (102) are charged safely and efficiently without risk of voltage-induced damage. Optionally, the voltage adjustments made by the bidirectional converters are dynamically controlled using a machine learning/artificial intelligence algorithm that analyses the optimal voltage levels for different battery chemistries, thus customizing the charging process to the specific characteristics of each type of battery (102).
[00047] In another embodiment, each docking unit (104) comprises a sensor to determine the SoC of the swappable battery (102) received within the corresponding docking unit (104). Each sensor is connected to the control arrangement (106). The connection of each sensor to the control arrangement (106), enables to provide real-time data on the charging status and energy levels of each swappable battery (102). Such a connectivity ensures that the control arrangement (106) can make informed decisions regarding energy distribution and charging priorities based on accurate and timely information. The presence of sensors enhances the precision of the SoC determinations while also contributing to the overall safety and efficiency of the charging process by preventing conditions such as overcharging or undercharging, which can significantly affect battery health. During operation, under a peak usage scenario where multiple electric vehicles return to the charging station simultaneously, a high demand is placed on the system (100). The sensors in each docking unit (104) rapidly assess the SoC of each swappable battery (102) upon connection. The control arrangement (106), informed by the real-time SoC data from the sensors, prioritizes the charging of the swappable batteries (102) with lower SoC or directs some swappable batteries (102) to discharge slightly to support others with critical power needs, thereby optimizing the responsiveness and efficiency of the system (102). Optionally, the sensors are integrated with internet-of-things (IoT) technology, enabling remote monitoring and management of SoC of each swappable battery (102) from a centralized system, enhancing the flexibility and scalability of the charging infrastructure.
[00048] In yet another embodiment, each docking unit (104) comprises an actuator to physically disconnect an electrical connection between the power supply grid (108) and the corresponding docking unit (104) and physically connect the first set and the second set. Such an actuator enhances the mechanical control over the electrical connections within the docking unit (104), allowing for rapid and robust manipulation of the power flow. Further, by physically disconnecting from the power supply grid (108) during disruptions or when advantageous (such as during high tariff periods), and by connecting sets of swappable batteries (102) for optimal charge balancing, the actuators facilitate precise management of electrical flows, thus ensuring operational reliability and extending the longevity of the SoC of the swappable batteries (102). Such a setup allows the system (100) to respond dynamically to changes in power availability or system requirements, enhancing the flexibility and responsiveness of the charging operations. During operation, when the system (100) encounters a power surge from the grid (108), the actuators within each docking unit (104) react by immediately disconnecting the electrical connection to the power supply grid (108), thereby protecting the swappable batteries (102) from potential overcharge or electrical damage. Simultaneously, the actuators connect the first set of swappable batteries (102) with lower SoC to the second set of swappable batteries (102) with higher SoC, ensuring that the charging can continue using the stored energy within the system (100), thus maintaining continuous operation without reliance on grid (108). Optionally, the actuators are implemented with haptic feedback mechanisms to provide physical alerts to maintenance personnel when disconnection or connection cycles occur, enhancing safety and awareness in the operational environment.
[00049] In an embodiment, each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit (104). The electric linear actuator provides precise movement of electrical connectors within the corresponding docking unit (104), enabling accurate and controlled connection and disconnection of the electrical circuits. The use of electric linear actuators ensures that the movements are smooth and highly responsive to the control signals from the control arrangement (106). Such a precision is critical in maintaining the integrity and efficiency of the power transfer processes, pre-setly when shifting loads between different battery sets or disconnecting from the power supply grid (108) in response to operational or environmental conditions. During operation, the electric linear actuators precisely adjust the electrical connectors to manage the load distribution effectively. For example, if a pre-set set of swappable batteries (102) requires rapid charging to meet a sudden demand, the actuators swiftly reconfigure the connections to prioritize power flow to these batteries, demonstrating the adaptability of the system (100) to fluctuating operational demands. Optionally, the system (100) employs pneumatic or hydraulic actuators for environments where electrical interference or explosive atmospheres might render electric components hazardous.
[00050] In another embodiment, the system (100) comprises a temperature sensor within each docking unit (104) to monitor a temperature of the corresponding swappable battery (102) received therein. The control arrangement (106) adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature. The data from the temperature sensors is relayed to the control arrangement (106), which adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature. Such a functionality is crucial for preventing overheating and ensuring optimal charging conditions, thereby preserving battery health and enhancing safety. Further, by continuously monitoring and adjusting the charge process based on real-time temperature data, the system (100) significantly improves the reliability and efficiency of battery charging operations, mitigating risks associated with thermal anomalies during the charging cycle. In an exemplary scenario, on a hot day, the temperature sensors in each docking unit (104) detect elevated temperatures in the swappable batteries (102). The control arrangement (106), upon receiving such information, reduces the charging rate or temporarily halts the charging to allow the swappable batteries (102) to cool down. Such an intervention prevents thermal stress on the swappable batteries (102), thereby extending lifespan thereof and maintaining performance within safe operational limits. Optionally, the temperature sensors are connected to humidity sensors to adjust the charging parameters not only based on temperature but also considering the humidity levels that might affect performance and health of the swappable batteries (102).
[00051] In an embodiment, the system (100) comprises a cooling arrangement connected to the control arrangement (106). The control arrangement (106) controls the cooling arrangement to manage the monitored temperature of each swappable battery (102) to preventing overheating. The cooling arrangement enables to manage the monitored temperature of each swappable battery (102) within the docking units (104). The control arrangement (106) actively controls the cooling arrangement based on the temperature data received from the sensors in each docking unit (104), thus ensuring that the swappable batteries (102) are maintained within optimal thermal conditions. Such an integration significantly enhances the safety and efficiency of the charging process by preventing overheating, which can lead to battery degradation or failure. Further, by actively managing the thermal environment of the swappable batteries (102), the system (100) extends the operational life and maintains the efficiency of the swappable batteries (102), pre-setly in conditions where thermal management is critical to preventing damage. In an exemplary operating scenario, during a summer peak load period where the ambient temperatures rise significantly, the thermal load on the swappable batteries (102) is increased during charging. The cooling arrangement, managed by the control arrangement (106), activates additional cooling measures to counteract the heat build-up. Such an operation can comprise, for example, increasing airflow, enhancing coolant circulation, or adjusting the charging rates to reduce thermal stress. Such proactive thermal management ensures that each swappable battery (102) is charged within its thermal tolerance limits, thus safeguarding battery health and performance during extreme conditions. Optionally, the cooling arrangement utilize phase change materials (PCMs) that absorb heat when the battery temperature rises, thereby passively controlling the temperature without the need for active cooling systems.
[00052] In another embodiment, the battery charging system (100) comprises a central power storage component. The electric current is supplied from the first set to the central power storage component and central power storage component to the second set. The central power storage component acts as an intermediary storage solution that receives electric current from the first set of swappable batteries (102) with lower SoC and then redistributes the electric current to the second set of swappable batteries (102) with higher SoC. The inclusion of the central power storage component allows for a more controlled and stable distribution of electric current within the system (100), enhancing the efficiency of power management. Such a setup ensures that energy is not wasted but rather stored and used effectively, maximizing the utility of the electric current generated or received by the system (100). Additionally, the central power storage component serves as a buffer, mitigating any sudden fluctuations in power demand or supply, thereby stabilizing the operational dynamics of the battery charging system (100). During operation, when there is a high demand for electric vehicles in the morning when many vehicles need fully charged batteries, the central power storage component collects and stores electric current from the power supply grid (108) during off-peak hours at night when electricity rates are lower. Subsequently, the power storage component distributes the stored energy to the swappable batteries (102) in the morning, ensuring that there is sufficient power available to meet the demand without overloading the grid (108) or incurring high energy costs. Thus, the present disclosure enhances the energy efficiency of the system (100) and ensures that electric vehicles have access to fully charged batteries exactly when needed, demonstrating the capability of the system (100) to adapt to usage patterns and energy pricing dynamically. Optionally, the central power storage component exports excess energy to the power supply grid (108) or other external systems, such as stationary energy storage solutions or backup power systems, making the system (108) versatile in broader energy management scenarios.
[00053] The battery charging system (100) provides an integrated solution for managing the charging process of swappable batteries (102) in electric vehicles, optimizing the utilization of available electrical infrastructure. By interacting with multiple docking units (104), the battery charging system (100) ensures that batteries with varied states of charge are efficiently charged, promoting a balanced usage of energy resources. The battery charging system (100) improves operational efficiency by automating the management of power distribution based on the state of charge, which minimizes the need for manual intervention and reduces operational downtime for electric vehicles awaiting fully charged batteries.
[00054] In an embodiment, each docking unit (104) individually determining the state of charge (SoC) of the swappable battery (102) allows for monitoring and targeted charging strategies, leading to improved battery life and performance. Such capability enables each docking unit (104) to customize the charging process based on the specific needs of each battery, which prevents overcharging and undercharging scenarios. By allowing each docking unit (104) to receive a swappable battery (102), the system enhances flexibility in handling a diverse range of battery types and capacities, thus accommodating various electric vehicle models without the need for separate charging setups.
[00055] In an embodiment, the control arrangement (106) dynamically adjusts the power supply by connecting to each docking unit (104), which facilitates an adaptive response to changes in grid (108) conditions and battery requirements. This response capability prevents potential damage to batteries due to inappropriate charging levels and helps maintain the stability of the power grid. Through the determination of a loss of supply from the power supply grid (108), the control arrangement (106) ensures continuous operation of the charging system by switching to alternative power sources or adjusting the charging rates, thus maintaining the reliability of the service even during grid failures.
[00056] In another embodiment, the control arrangement (106) with the power supply grid (108) allows for the harnessing of electricity from grind (108) to charge electric vehicles efficiently, making use of off-peak tariffs and renewable energy sources whenever available. This strategic utilization of grid power can lead to cost savings and reduced environmental impact. The power supply grid (108) supports the system’s ability to draw on a robust energy network, enhancing the system’s capability to provide uninterrupted service to a large number of electric vehicles, which is critical in high-demand scenarios. Further, identification and utilization of the first set of swappable batteries (102) with a SoC lower than a preset threshold for supplying power to other batteries enables efficient approach to energy management, where undercharged batteries are use as power source to charge other batteries such that batteries are charged at possible maximum charge levels for immediate deployment. This method reduces waiting times for vehicles that need fully charged batteries quickly, enhancing the overall efficiency of fleet operations.
[00057] In another embodiment, the battery charging system (100) allows for dynamic tariff management through the control arrangement (106), which monitors current electric tariffs. If the tariff exceeds a set threshold, the control arrangement (106) disconnects the power supply grid (108) from each swappable battery (102) to prevent charging during high-tariff periods. This feature reduces operational costs by avoiding electricity usage when costs are highest. Additionally, the control arrangement (106) facilitates the redistribution of electric current from the first set of swappable batteries (102) to the second set when tariffs are elevated, ensuring optimal usage of stored energy and maintaining battery charge levels without additional power consumption from grid (108).
[00058] The control arrangement (106) coordinates with these relays to selectively connect or disconnect the power supply grid (108) from each swappable battery (102). This segregation allows for targeted charging or discharging of batteries based on real-time power requirements and condition of grid (108), thereby enhancing the efficiency of power management within the system (100). The mechanical relay, controlled by the control arrangement (106), also enables the transfer of electric current from the first set of swappable batteries to the second set, thus supporting continuous energy supply even during grid outages. This system element provides an uninterrupted power supply, increasing the reliability and operational uptime of the system.
[00059] In an embodiment, the bidirectional converters facilitate the adjustment of voltage levels between the first and second sets of swappable batteries (102) to enable compatibility between different battery groups and optimizes the power transfer process, thus safeguarding battery health and enhancing the overall efficiency of the charging system. Actuators within each docking unit (104), specifically electric linear actuators, provide physical manipulation of electrical connections. These actuators enable or disable connections to the power supply grid (108) and between battery sets. This physical control mechanism facilitates rapid response to changes in power demand or supply conditions, enhancing the adaptability and responsiveness of the charging system to external changes.
[00060] In an embodiment, temperature sensor enables precise monitoring of the temperature of the corresponding swappable battery (102) to enable adjustment of electric current supplied to each swappable battery (102) based on its specific temperature condition. Such regulation of electric current enhances the safety of the battery charging system by reducing the risk of thermal runaway in the swappable batteries (102). Moreover, the adjustment of electric current depending on the temperature contributes to optimizing the charging cycle, which in turn extends the lifespan of the swappable batteries (102). Additionally, the ability to monitor and adjust for temperature variations ensures consistent performance across all batteries, leading to improved reliability of the battery charging system (100). Further, cooling arrangement enables active management of the temperature of each swappable battery (102). By actively controlling the cooling based on real-time temperature data, the battery charging system (100) prevents overheating, thereby safeguarding against potential damage from excessive heat.
[00061] In an embodiment, the system (100) can utilize sensing arrangement for each of docking units (104), wherein the sensing arrangement can comprise various sensors for measurement of various battery parameters. For determining the charge level of each battery, voltage sensors can be utilized, wherein the voltage sensor enable measurement of voltage across the battery terminals to infer the state of charge (SoC). To assess the health of each battery, impedance sensor can be employed to analyze the internal resistance of the battery, providing insights into its overall health and efficiency. For tracking the charge/discharge cycles, a combination of current sensors and an integrated battery management system (BMS) records and calculates the number of cycles each battery undergoes. For measurement of energy density or capacity of each battery, coulomb counters can be used to measure the total charge that moves in and out of the battery, which, when combined with voltage measurements, provides an accurate estimate of energy density. To sense energy storage capacity, a combination of coulomb counters and specific energy sensors, which evaluate the energy capacity per unit mass or volume, is used. To measure the maximum charging current handling capability of each battery (102), high-precision current sensors can be implemented to monitor the maximum current (102) battery can safely handle during charging.
[00062] Fig. 2 illustrates an exemplary flow diagram about operational procedure of a charging system for swappable batteries (102) used in electric vehicles, in accordance with embodiment of present disclosure. The process begins by determining the state of charge (SoC) of the batteries (102) to assess current energy levels thereof. Following the SoC assessment, the control arrangement (106) evaluates the status of the power supply from the grid. If the power supply from the grid (108) is stable and uninterrupted, the control arrangement (106) enables charging of each battery (102) using energy of power grid. However, if there is a loss of power from the grid, the control arrangement (106) takes an alternative course of action. The control arrangement (106) categorizes the batteries (102) into two sets based on their SoC levels. The batteries (102) with a SoC above the preset threshold are grouped into the second set, indicating they have higher energy reserves. Conversely, the batteries (102) with a SoC below the threshold are placed in the first set, indicating lower energy reserves. After categorization, the control arrangement (106) activates a contingency plan where the batteries (102) from the first set (lower SoC) are used to enable the charging of the batteries (102) in the second set (higher SoC). This redistribution of power helps maintain continuous charging operations and to provide maximum number of batteries (102) with maximum charge level. Thus, the present disclosure enables charging station can operate effectively by utilizing the stored energy within the batteries (102) to maintain a seamless supply of charged batteries (102) for electric vehicles.
[00063] Fig. 3 shows a flow diagram to present the operational procedure of a battery charging system for electric vehicles, particularly focusing on how charging station adapts to various power supply conditions to maintain efficient charging. The control arrangement (106) activates sensing apparatus to measure SoC of each battery (102) received within docking units (104). Following the SoC assessment, the control arrangement (106) checks for any power loss from the grid (108). If there is a power loss, the control arrangement (106) activates emergency protocol. The control arrangement (106) categorizes all batteries (102) into two sets: those above a predefined SoC threshold (i.e., second set) and those below (i.e., first set). If the power cut is existed, the control arrangement (106) leverages the stored energy from the batteries (102) of first category to charge batteries (102) of second category to enabling continuous operation without relying on the grid energy. If there is no power loss, the control arrangement (106) monitors the electric tariff, a critical cost-control measure. Tariff monitoring allows the control arrangement (106) to optimize charging costs, which can vary significantly during the day or night. If the monitored tariff is above a certain cost threshold, the control arrangement (106) concludes that charging based on grid energy would be economically expensive due to high costs. In such a scenario, the control arrangement (106) disconnects grid supply and, similar to the power loss scenario, will rely on the internal redistribution of power from batteries (102) of first category to charge the batteries (102) of second category to optimize charging costs. Conversely, if the tariff is not above the threshold, the control arrangement (106) continues to charge the batteries normally using grid power, taking advantage of lower-cost electricity. Thus, terrif based charging energy source selection decision enables that the charging operations are cost-effective, maintaining the system's efficiency and reducing operational expenses. Thus, the present disclosure provides adaptive approach to managing power supply and costs via real-time tariff monitoring and strategic power redistribution ensures that the battery charging station operates optimally, balancing energy use with cost efficiency and system reliability. Such smart energy management practices are essential in the context of fluctuating energy prices and varying grid stability, ensuring that the charging infrastructure for electric vehicles is both sustainable and economically viable.
[00064] Example embodiments herein have been described above with reference to block diagrams and flowchart illustrations of methods and apparatuses. It will be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by various means including hardware, software, firmware, and a combination thereof. For example, in one embodiment, each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations can be implemented by computer program instructions. These computer program instructions may be loaded onto a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions which execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
[00065] Throughout the present disclosure, the term ‘processing means’ or ‘microprocessor’ or ‘processor’ or ‘processors’ includes, but is not limited to, a general purpose processor (such as, for example, a complex instruction set computing (CISC) microprocessor, a reduced instruction set computing (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, a microprocessor implementing other types of instruction sets, or a microprocessor implementing a combination of types of instruction sets) or a specialized processor (such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), or a network processor).
[00066] The term “non-transitory storage device” or “storage” or “memory,” as used herein relates to a random-access memory, read only memory and variants thereof, in which a computer can store data or software for any duration.
[00067] Operations in accordance with a variety of aspects of the disclosure is described above would not have to be performed in the precise order described. Rather, various steps can be handled in reverse order or simultaneously or not at all.
[00068] While several implementations have been described and illustrated herein, a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein may be utilized, and each of such variations and/or modifications is deemed to be within the scope of the implementations described herein. More generally, all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific implementations described herein. It is, therefore, to be understood that the foregoing implementations are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, implementations may be practiced otherwise than as specifically described and claimed. Implementations of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

BATTERY CHARGING SYSTEM FOR CHARGING SWAPPABLE BATTERIES OF ELECTRIC VEHICLES

Field of the Invention
[0001] The present disclosure generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.

Background
[0002] The description in the Background section includes general information related to the field of the present application. The background is only meant to provide context to a reader in understanding the present invention. It is neither to be taken as an admission that any of the provided information relates to prior art for the presently claimed invention nor that any publication explicitly or implicitly referenced within this section relates to prior art. The background section is merely meant to be illustrative rather than exhaustive and is primarily intended to identify problems associated with the present state of the art.
[0003] Electric vehicles (EVs) rely on efficient battery management systems to optimize performance and extend operational capabilities. Generally, multiple solutions are known for managing the charging of swappable batteries in EVs. One such well-known system involves using individual docking units that can charge batteries directly from a power supply grid. Such systems focus on providing a consistent charge to each battery, ensuring that the EVs can be rapidly serviced and returned to use.
[0004] Usually, another commonly employed technique involves advanced monitoring of the state of charge (SoC) of each battery. Conventionally, systems incorporating SoC monitoring are capable of assessing the precise energy levels of batteries, enabling targeted charging that can prolong battery life and reduce wear. However, these systems often depend heavily on a continuous power supply from the grid, which can be a critical drawback during power outages or when grid electricity prices are high.
[0005] Problems associated with the aforesaid systems include their inability to adapt to external power supply issues such as grid failures or fluctuating energy costs. Additionally, while individual SoC monitoring provides valuable data, many systems do not utilize such data to optimize the distribution of charge between batteries under varying grid conditions.
[0006] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for efficiently managing the charging of swappable batteries in electric vehicles.
Summary
[0007] The following Summary section provides only a brief introduction to the various embodiments of the present invention. It is to be understood that the following paragraphs are neither meant to constitute a complete and thorough description of the claimed subject matter nor is it intended to define the technical features or the scope of the claimed subject matter. Thus, the description in the Summary section is neither intended to identify only the essential features of the present invention nor limit the scope of the claimed subject matter in any manner.
[0008] The present invention generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.
[0009] In an aspect, the present disclosure provides a battery charging system for charging swappable batteries of electric vehicles. The system comprises multiple docking units, wherein each docking unit receives a swappable battery and determines a state of charge (SoC) of the swappable battery received within the corresponding docking unit. The system comprises a control arrangement connected to each docking unit, wherein the control arrangement enables supply of electric current from a power supply grid to each swappable battery received within the multiple docking units to charge the corresponding swappable battery and wherein the control arrangement determines loss of supply of electric current from the power supply grid; identifies a first set of the swappable batteries having the SoC lower than a pre-set threshold; a second set of the swappable batteries having the SoC higher than the pre-set threshold, wherein the pre-set threshold is less than 100% SoC of the swappable batteries of the second set; and causes supply of electric current from the first set of swappable batteries to the second set of swappable batteries to enable charging of each swappable battery of the second set to charge close to maximum (i.e., 100% SoC).
[00010] In an embodiment, the control arrangement disconnects the supply of electric current from the power supply grid to each swappable battery received within the multiple docking units based on an increase in electric current tariff more than a tariff limit and wherein the control arrangement causes the supply of electric current from the first set of swappable batteries to the second set of swappable batteries.
[00011] In another embodiment, each docking unit comprises a mechanical relay to disconnect the supply of electric current between the power supply grid and each swappable battery received within the multiple docking units and wherein the control arrangement is connected to each mechanical relay to cause the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid.
[00012] In yet another embodiment, the control arrangement controls each mechanical relay to enable the supply of electric current from the first set to the second set.
[00013] In still another embodiment, each docking unit comprises a bidirectional converter to manage the supply of electric current from the first set to the second set.
[00014] In another embodiment, the bidirectional converter adjusts voltage levels between the first set and the second set.
[00015] In yet another embodiment, each docking unit comprises a sensor to determine the SoC of the swappable battery received within the corresponding docking unit and wherein each sensor is connected to the control arrangement.
[00016] In still another embodiment, each docking unit comprises an actuator to physically disconnect an electrical connection between the power supply grid and the corresponding docking unit; and physically connect the first set and the second set.
[00017] In another embodiment, each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit.
[00018] In yet another embodiment, the system comprises a temperature sensor within each docking unit to monitor a temperature of the corresponding swappable battery received therein and wherein the control arrangement adjusts the supply of electric current to the corresponding swappable battery based on the monitored temperature.
[00019] In still another embodiment, the system comprises a cooling arrangement connected to the control arrangement and wherein the control arrangement controls the cooling arrangement to manage the monitored temperature of each swappable battery to preventing overheating.
[00020] In another embodiment, the battery charging system comprises a central power storage component and wherein the electric current is supplied from the first set to the central power storage component; and central power storage component to the second set.
[00021] The various objects, features, and advantages of the claimed invention will become clear when reading the following Detailed Description along with the Drawings.
Brief Description of the Drawings
[00022] The following Brief Description of Drawings section will be better understood when read in conjunction with the appended drawings. Although exemplary embodiments of the present invention are illustrated in the drawings, the embodiments are not limited to the specific features shown in the drawings. The drawings illustrate simplified views of the claimed invention and are therefore, not made to scale. Identical numbers in the drawings indicate like elements in the drawings.
[00023] The embodiments of the present invention will now be briefly described by way of example only with reference to the drawings in which:
[00024] FIG. 1 shows a schematic illustration of a battery charging system for charging swappable batteries of electric vehicles, in accordance with an embodiment of the present disclosure.
[00025] Fig. 2 illustrates an exemplary flow diagram about operational procedure of a charging system for swappable batteries used in electric vehicles, in accordance with embodiment of present disclosure.
[00026] Fig. 3 shows a flow diagram to present the operational procedure of a battery charging system for electric vehicles, particularly focusing on how charging station adapts to various power supply conditions to maintain efficient charging, in accordance with an embodiment of the present disclosure.
Detailed Description
[00027] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any single embodiment. The scope of the invention encompasses without limitation numerous alternatives, modifications and combinations.
[00028] It shall be noted that as used within the current section as well as in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Further, the use of words such as “first”, “second”, “third” and the like does not represent any particular order. Such words have been merely employed to distinguish one individual component from another. Moreover, “each” refers to each member of a set or each member of a subset of a set.
[00029] An arrangement of two or more components, unless stated specifically, can be done without limitation in any manner relative to a three-dimensional coordinate system. Thus, a second component arranged underneath a first component may also be taken to mean that the first component is arranged underneath the second component.
[00030] The phrase “configured to” as used through the Detailed Description as well as the appended Claims is to be taken to mean that the particular component that is configured to perform a specific action is specially conceived, designed and subsequently manufactured to enable the particular component to be employed for conveniently performing the specific action. However, this should not be taken to mean that the particular component is only capable of performing one specific action that the particular component is configured to do. It may perform a variety of different actions in addition to the specific action that the particular component has been configured to do.
[00031] The phrase “operably coupled” as used throughout the Detailed Description as well as the appended Claims is to be understood to refer to a coupling between two or more components that such an action performed by or on a first of the components is transferrable as an equivalent action of or on a second of the component that is operably coupled to the first component. It will be appreciated that more than two components may be operably coupled to each other.
[00032] Terms such as “slidably”, “pivotally”, “rotatably” and the like have been employed throughout the Detailed Description as well as the appended Claims to refer to coupling between two or more components such that a first component can move (such as, slide, pivot or rotate) with respect to a second component that is movably coupled to the first component without completely detaching from the first component. It will be appreciated that more than two components may be operably coupled to each other.
[00033] It will be appreciated that various components of the system may be permanently or temporarily (such as, detachably) coupled to each other using various permanent or temporary means, including but not limited to, welding the components together, using screws, nuts, bolts and the like to join the components together, attaching the components using magnets and the like. Such details are commonly available in the art and have therefore been omitted throughout the Detailed Description and the appended Claims for the sake of conciseness.
[00034] It will also be appreciated that modifications, additions, or omissions may be made to the systems and apparatuses described hereinafter without departing from the scope of the Claims. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components.
[00035] The present invention generally relates to battery charging systems for electric vehicles and particularly to a system for charging swappable batteries based on state of charge of the swappable batteries.
[00036] Referring to FIG. 1, there is shown a schematic illustration of a battery charging system (100) for charging swappable batteries (102) of electric vehicles, in accordance with an embodiment of the present disclosure. The system (100) comprises multiple docking units (104). Each docking unit (104) receives a swappable battery (102). Further, each docking unit (104) determines a state of charge (SoC) of the swappable battery (102) received within the corresponding docking unit (104). Each docking unit (104) serves as a receptacle for a swappable battery (102), providing mechanical support and electrical connections necessary for charging. The docking units (104) are equipped with sensors and electronic circuits to assess the SoC of each swappable battery (102), thereby enabling individual monitoring and management of the charging process according to requirements of each swappable battery (102). Optionally, each docking unit (104) can be implemented with a user interface to display the charging status and SoC directly at the docking unit (104). Thus, the docking units (104) enable the physical accommodation of the swappable batteries (102) therein while also ensuring that the SoC is accurately measured, thereby, maintaining battery health and extending the lifespan of the swappable batteries (102) by preventing overcharging.
[00037] The system (100) further comprises a control arrangement (106) connected to each docking unit (104). The control arrangement (106) enables supply of electric current from a power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) to charge the corresponding swappable battery (102). The control arrangement (106) is central to managing the operational aspects of the system (100) as the control arrangement (106) controls the flow of electric current from the power supply grid (108) to the swappable batteries (102) based on the SoC data received from the docking units (104). The power supply grid (108) provides the necessary electrical current for charging the swappable batteries (102). The power supply grid (108) is connected to the control arrangement (106). The control arrangement (106) draws electric current from a power supply grid (108) and distributes the electric current among the swappable batteries (102) received into the multiple docking units (104), thereby enabling the charging of each swappable battery (102) according to individual charging requirements and current SoC thereof. Consequently, the control arrangement (106) optimizes the charging process for efficiency and effectiveness. Further, the control arrangement (106) is adapted to monitor the continuity of electric current supply from the power supply grid (108), ensuring that operation of the system (100) is seamless and uninterrupted. Optionally, the control arrangement (106) is connected to each docking unit (104) using wired or wireless communication methods such as Wi-Fi, Bluetooth, or ZigBee to facilitate real-time data exchange and system management.
[00038] Further, the control arrangement (106) determines loss of supply of electric current from the power supply grid (108). In response, the control arrangement (106) identifies a first set of the swappable batteries (102) having the SoC lower than a pre-set threshold and a second set of the swappable batteries (102) having the SoC higher than the pre-set threshold, such that the pre-set threshold is less than 100% SoC of the swappable batteries (102) of the second set. Thereafter, the control arrangement (106) causes supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102) to enable the SoC of each swappable battery (102) of the second set to charge to 100% SoC. In the event of a power outage or reduction in power supply from the grid (108), the control arrangement (106) manages the transfer of electric current between batteries (102) from the first set with lower SoC to those in the second set with higher SoC, ensuring optimal battery (102) usage and efficiency. The control arrangement (106) is capable of identifying two distinct sets of swappable batteries (102), such as the first set with an SoC lower than a pre-set threshold (e.g., 30%, 40%, 50%, 55% etc.) and the second set with an SoC higher than the same threshold. Such a categorization allows the control arrangement (106) to manage the available resources effectively by initiating the transfer of electric current from the first set of swappable batteries (102) to the second set. The transfer is facilitated to enable each swappable battery (102) in the second set to reach a full charge, or 100% SoC. The ability to redistribute electric current in the aforesaid manner significantly enhances efficiency of charging system (100) against power disruptions, ensuring that the most charged batteries (102) reach full capacity, thereby maximizing the readiness and utility of the entire fleet of swappable batteries (102). Optionally, the control arrangement (106) may receive advance notification of upcoming power outages from municipality or government servers. In response, the control arrangement (106) swiftly initiates a protocol to maintain charging operations by reallocating electric current from batteries (102) in the first set with lower SoC to those in the second set with higher SoC, thus ensuring continuous operation without interruption. For example, such an operation of the system (100) enables the control arrangement (106) to proactively redistribute electric current among the swappable batteries (102), thereby maintaining uninterrupted charging operations and preventing potential disruptions in electric vehicle usage due to uncharged batteries.
[00039] The pre-set threshold for the SoC can be dynamically determined by the control arrangement (106) based on several factors that ensure the efficient operation of the system, particularly during interruptions in power supply from the grid (108). Consider a scenario involving charging system (100) with 10 docking units (104), each configured to accommodate a swappable battery (102) for electric vehicles. Out of 10, let's assume 7 docking units (104) contain batteries (102) with varied SoCs. Upon detection disruption in the power supply from the grid (108), the control arrangement (106) analyses the SoC of each battery (102) currently in the docking units (104). Based on analysis, the control arrangement (106) computes an average SoC (i.e., pre-set threshold) or another statistical measure (median, mode, etc.) that best represents the overall energy availability within the system. For instance, if the SoCs are spread between 20% to 90%, the control arrangement might set pre-set threshold at 50% to effectively divide the batteries (102) into two operational groups as first set of batteries (102) with SoC less than 50% (lower energy reserve) and second set of batteries (102) with SoC greater than 50% (higher energy reserve). For dynamic determination of pre-set threshold, control arrangement (106) utilizes several factors such as statistical distribution of charge levels of each battery (102), health of each battery (102), charge/discharge cycles of each battery (102), voltage level of each battery (102), energy density or capacity of each battery (102). For instance, the statistical distribution of battery charge levels involves an aggregate assessment of SoC across all batteries (102) in the station. Suppose the range of SoC varies from 20% to 90% among the batteries (102). By calculating the median or mean, the control arrangement (106) can identify 50% SoC as pre-set threshold. The statistical approach enables that batteries (102) are categorized effectively, maintaining a balance between those needing more charge and those ready to discharge or support the system (100) during high-demand periods. The control arrangement (106) For battery health or SOH of current operational capacity of each battery (102) relative to original specifications thereof. For example, battery (102) that originally held 100 ampere-hours might now hold only 70 ampere-hours due to degradation over time. If the threshold for optimal performance is set at 80 ampere-hours, such battery (102) would fall below the threshold and thereby categorized in first category. Furthermore, charge/discharge cycles each battery (102) also be considered by control arrangement (106). Batteries (102) that have undergone a significant number of cycles, say over 1000 cycles, are likely to exhibit reduced efficiency. For instance, battery (102) designed to withstand 1500 cycles might start showing considerable efficiency loss at cycle 1000. By considering charge/discharge cycle, the control arrangement (106) can categorize such batteries (102) as having lower energy reserves (i.e., first category) to prevent overuse thereof in critical conditions. Furthermore, voltage levels of each battery (102) can be used by control arrangement (106) to determine operational readiness of each battery (102). The battery (102) that consistently shows a voltage level below nominal range thereof, perhaps due to internal resistance or age-related degradation, would be categorized under the lower reserve. For example, if a nominal voltage is 12 volts but a particular battery (102) frequently drops to 10 volts, which indicates instability or reduced capacity, results in categorization into the lower reserve set. The energy density measures the amount of energy battery (102) can store relative to size or weight thereof, directly affecting utility and performance. The battery (102) with high energy density can deliver more power without requiring frequent recharges, ideal for inclusion in the higher energy reserve category, which can be used in EV to provide higher range. Conversely, batteries (102) with lower energy density, which might deliver sufficient power but require more frequent charging and larger physical space, are better suited for the lower energy reserve category. For instance, if the average energy density in the station's battery (102) inventory is 200 watt-hours but several batteries (102) measure only 150 watt-hours, such battery (102) would be categorized as lower energy reserves due to their less efficient energy storage capacity.
[00040] In an embodiment, the control arrangement (106) enables charging process by selecting and preparing batteries (102). Consider a station where batteries (102) vary significantly in their state of charge (SoC), health, and other parameters. To initiate fast charging, the control arrangement (106) can first identify one battery (102) from second set to receive electrical energy from the each of first set of batteries (102) for rapid charge of selected battery (102). Selection of battery (102) from second set can be based on critical requirement, pre-booking status, energy storage capacity, maximum charging current handling capability and the like. Once the battery (102) is selected, control arrangement (106) enables transfer of electrical energy from first set of batteries (102) to the selected batteries (102) of second set. Upon full complete charging, control arrangement (106) selects another battery (102) from second set. This process is continued till all batteries (102) are charged either fully or greater than pre-defined level. The one-by-one charging of batteries (102) can enable that swapping station effectively manages resources during grid interruptions, maintaining supply of maximum number of charged batteries (102) for electric vehicle operations.
[00041] The battery charging system (100) significantly enhances the efficiency of charging operations for swappable batteries of electric vehicles by allowing individualized charging management based on real-time SoC evaluations. The presence of multiple docking units (104) enables simultaneous charging of multiple swappable batteries (102) without affecting the charging of any other swappable battery (102), which is crucial in high-demand scenarios such as electric vehicle charging stations. Additionally, the adaptive power management capabilities of the control arrangement (106) ensure optimal power utilization, reducing waste and improving the overall energy efficiency of the system. The incorporation of intelligent and adaptive charging strategies not only improves the operational efficiency of the charging system (100) but also contributes to the overall sustainability of electric vehicle operations. It will be appreciated that by optimizing the usage of electric power and reducing dependency on constant power supply, the system (100) enhances the energy efficiency and reliability of electric vehicle charging infrastructure. Further, the comprehensive approach to managing the charging of swappable batteries in electric vehicles ensures that the battery charging system (100) remains effective under various operating conditions, thus enhancing the reliability and efficiency of electric vehicle infrastructures. Optionally, the docking units (104) incorporate solar panels on surfaces thereof, enabling the docking units (104) to harness solar energy to supplement the charging of the swappable batteries (102). Consequently, the incorporation of the solar panels makes the system (100) more sustainable while also allowing the system (100) to function in remote areas without reliable access to power supply from power supply grids (108).
[00042] In an embodiment, the control arrangement (106) monitors a present electric tariff (e.g., ? 4/kWh to ? 6/kWh) or receives data related present electric tariff from grid management server or system administrator or operator. The control arrangement (106) disconnects the supply of electric current from the power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) based on monitored or received present tariff. For instance, if the present electric tariff (e.g., ? 10/kWh) is higher than a predetermined tariff (e.g., ? 8/kWh). Subsequently, the control arrangement (106) causes the supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102). The control arrangement (106) is associated with the capability of disconnecting the supply of electric current from the power supply grid (108) to each swappable battery (102) in response to an increase in the electric current tariff exceeding a predetermined limit. Consequently, the control arrangement (106) enables cost-efficiency, allowing the system (100) to operate economically by leveraging lower-cost electric power during off-peak hours and reducing consumption during peak tariff periods. Subsequently, the control arrangement (106) manages the energy resources by facilitating the supply of electric current from the first set of swappable batteries (102), which have lower SoC, to the second set with higher SoC. Such an operation ensures optimal charge management of battery (102) while also enhancing the economic operation of the system (100) by utilizing stored energy in a strategic manner, thus minimizing the impact of high energy costs. Optionally, such a dynamic tariff response capability can be integrated with a real-time energy pricing feed from utility providers, allowing the system (100) to automatically adjust operation based on current energy prices, further optimizing energy costs and efficiency. Thus, during a peak tariff period, the control arrangement (106) detects an increase in energy costs through connection thereof to real-time utility pricing data. The control arrangement (106) responds by disconnecting the electric current supply from the power supply grid (108) and simultaneously, initiates the transfer of stored electric current from the swappable batteries (102) in the first set with lower SoC to the swappable batteries (102) in the second set with higher SoC. Such a strategic management maintains the charging operation without reliance on the expensive power from grid (108) while also optimizing the energy usage of the system (100) by drawing on cheaper stored energy, thereby enhancing the cost-efficiency of the operation. Optionally, the control arrangement (106) employs machine learning algorithms to predict patterns in electricity tariff changes, thus, allowing the system (100) to anticipate cost spikes and adjust charging strategy proactively, further optimizing energy costs.
[00043] In another embodiment, each docking unit (104) comprises a mechanical relay to disconnect the supply of electric current between the power supply grid (108) and each swappable battery (102) received within the multiple docking units (104). The control arrangement (106) is connected to each mechanical relay to manage (e.g., ON or OFF) the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid (108). The inclusion of mechanical relays enhances the reliability and safety of the system (100) by providing a robust means of physically isolating electrical circuits, thus preventing potential electrical faults and improving the overall resilience of the system (100). Such a setup allows for an immediate response to power disruptions, ensuring that the charging process can continue seamlessly without relying solely on the power supply grid (108). Optionally, each mechanical relay in the docking units (104) is be equipped with sensors that detect the physical condition of the relay, such as wear or damage, alerting the system (100) to perform maintenance or replacement pre-emptively, thus avoiding potential failures.
[00044] In yet another embodiment, the control arrangement (106) controls each mechanical relay to enable the supply of electric current from the first set to the second set. The control arrangement (106) actively controls each mechanical relay to enable the redirection of electric current from the first set of swappable batteries (102) with lower SoC to the second set of swappable batteries (102) with higher SoC, effectively balancing the charge levels of batteries (102) across the system (100). Such an operation ensures that all swappable batteries (102) reach optimal charge levels efficiently, enhancing the readiness of the swappable batteries (102) for use in electric vehicles. The capability to manage such relays by the control arrangement (106) precisely allows the system (100) to maintain continuous operation and extend the operational lifespan of the swappable batteries (102) by preventing scenarios of deep discharge or overcharge, thus maximizing the utility and efficiency of the swappable batteries (102). Optionally, the system (100) employs solid-state relays for faster switching speeds and reduced maintenance requirements, thereby enhancing the reliability and speed of switching between power sources.
[00045] In still another embodiment, each docking unit (104) comprises a bidirectional converter to manage the supply of electric current from the first set to the second set. The bidirectional converter enables the efficient charging of the swappable batteries (102) from the power supply grid (108) while also facilitating the transfer of electric current from the first set of swappable batteries (102) with lower SoC to the second set with higher SoC. The bidirectional converter further supports both the intake of electric current from the power supply grid (108) and the redistribution among the swappable batteries (102), ensuring a continuous and efficient charge cycle. Such a capability significantly enhances the adaptability of the system (100) to varying power co

converter shifts to redistribute electricity from the first set of swappable batteries (102) with lower SoC to the second set with higher SoC, thus ensuring a balanced and continuous charging process. Optionally, the bidirectional converters are designed to work with different types of energy storage systems, such as supercapacitors, allowing for rapid energy transfer capabilities and supporting applications requiring quick bursts of energy.
[00046] In an embodiment, the bidirectional converter adjusts voltage levels between the first set and the second set. Such a function of voltage management is critical in managing the differences in voltage requirements between the different sets of swappable batteries (102), ensuring that the transfer of electric current does not lead to overvoltage or undervoltage conditions, which could damage the swappable batteries (102). Further, by adjusting voltage levels appropriately, the bidirectional converter ensures that each swappable battery (102) is charged in the most efficient and safe manner possible, thereby maximizing the lifespan and performance of the swappable batteries (102). The voltage adjustment capability also allows for a more flexible energy distribution strategy, accommodating various battery technologies and specifications within the system (100). During operation, if a significant variance in the voltage requirements between the first and second sets of swappable batteries (102) is determined due to differing charge levels or battery technologies, the bidirectional converter adjusts the voltage levels during the transfer of power from the first set to the second set, thus ensuring that all swappable batteries (102) are charged safely and efficiently without risk of voltage-induced damage. Optionally, the voltage adjustments made by the bidirectional converters are dynamically controlled using a machine learning/artificial intelligence algorithm that analyses the optimal voltage levels for different battery chemistries, thus customizing the charging process to the specific characteristics of each type of battery (102).
[00047] In another embodiment, each docking unit (104) comprises a sensor to determine the SoC of the swappable battery (102) received within the corresponding docking unit (104). Each sensor is connected to the control arrangement (106). The connection of each sensor to the control arrangement (106), enables to provide real-time data on the charging status and energy levels of each swappable battery (102). Such a connectivity ensures that the control arrangement (106) can make informed decisions regarding energy distribution and charging priorities based on accurate and timely information. The presence of sensors enhances the precision of the SoC determinations while also contributing to the overall safety and efficiency of the charging process by preventing conditions such as overcharging or undercharging, which can significantly affect battery health. During operation, under a peak usage scenario where multiple electric vehicles return to the charging station simultaneously, a high demand is placed on the system (100). The sensors in each docking unit (104) rapidly assess the SoC of each swappable battery (102) upon connection. The control arrangement (106), informed by the real-time SoC data from the sensors, prioritizes the charging of the swappable batteries (102) with lower SoC or directs some swappable batteries (102) to discharge slightly to support others with critical power needs, thereby optimizing the responsiveness and efficiency of the system (102). Optionally, the sensors are integrated with internet-of-things (IoT) technology, enabling remote monitoring and management of SoC of each swappable battery (102) from a centralized system, enhancing the flexibility and scalability of the charging infrastructure.
[00048] In yet another embodiment, each docking unit (104) comprises an actuator to physically disconnect an electrical connection between the power supply grid (108) and the corresponding docking unit (104) and physically connect the first set and the second set. Such an actuator enhances the mechanical control over the electrical connections within the docking unit (104), allowing for rapid and robust manipulation of the power flow. Further, by physically disconnecting from the power supply grid (108) during disruptions or when advantageous (such as during high tariff periods), and by connecting sets of swappable batteries (102) for optimal charge balancing, the actuators facilitate precise management of electrical flows, thus ensuring operational reliability and extending the longevity of the SoC of the swappable batteries (102). Such a setup allows the system (100) to respond dynamically to changes in power availability or system requirements, enhancing the flexibility and responsiveness of the charging operations. During operation, when the system (100) encounters a power surge from the grid (108), the actuators within each docking unit (104) react by immediately disconnecting the electrical connection to the power supply grid (108), thereby protecting the swappable batteries (102) from potential overcharge or electrical damage. Simultaneously, the actuators connect the first set of swappable batteries (102) with lower SoC to the second set of swappable batteries (102) with higher SoC, ensuring that the charging can continue using the stored energy within the system (100), thus maintaining continuous operation without reliance on grid (108). Optionally, the actuators are implemented with haptic feedback mechanisms to provide physical alerts to maintenance personnel when disconnection or connection cycles occur, enhancing safety and awareness in the operational environment.
[00049] In an embodiment, each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit (104). The electric linear actuator provides precise movement of electrical connectors within the corresponding docking unit (104), enabling accurate and controlled connection and disconnection of the electrical circuits. The use of electric linear actuators ensures that the movements are smooth and highly responsive to the control signals from the control arrangement (106). Such a precision is critical in maintaining the integrity and efficiency of the power transfer processes, pre-setly when shifting loads between different battery sets or disconnecting from the power supply grid (108) in response to operational or environmental conditions. During operation, the electric linear actuators precisely adjust the electrical connectors to manage the load distribution effectively. For example, if a pre-set set of swappable batteries (102) requires rapid charging to meet a sudden demand, the actuators swiftly reconfigure the connections to prioritize power flow to these batteries, demonstrating the adaptability of the system (100) to fluctuating operational demands. Optionally, the system (100) employs pneumatic or hydraulic actuators for environments where electrical interference or explosive atmospheres might render electric components hazardous.
[00050] In another embodiment, the system (100) comprises a temperature sensor within each docking unit (104) to monitor a temperature of the corresponding swappable battery (102) received therein. The control arrangement (106) adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature. The data from the temperature sensors is relayed to the control arrangement (106), which adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature. Such a functionality is crucial for preventing overheating and ensuring optimal charging conditions, thereby preserving battery health and enhancing safety. Further, by continuously monitoring and adjusting the charge process based on real-time temperature data, the system (100) significantly improves the reliability and efficiency of battery charging operations, mitigating risks associated with thermal anomalies during the charging cycle. In an exemplary scenario, on a hot day, the temperature sensors in each docking unit (104) detect elevated temperatures in the swappable batteries (102). The control arrangement (106), upon receiving such information, reduces the charging rate or temporarily halts the charging to allow the swappable batteries (102) to cool down. Such an intervention prevents thermal stress on the swappable batteries (102), thereby extending lifespan thereof and maintaining performance within safe operational limits. Optionally, the temperature sensors are connected to humidity sensors to adjust the charging parameters not only based on temperature but also considering the humidity levels that might affect performance and health of the swappable batteries (102).
[00051] In an embodiment, the system (100) comprises a cooling arrangement connected to the control arrangement (106). The control arrangement (106) controls the cooling arrangement to manage the monitored temperature of each swappable battery (102) to preventing overheating. The cooling arrangement enables to manage the monitored temperature of each swappable battery (102) within the docking units (104). The control arrangement (106) actively controls the cooling arrangement based on the temperature data received from the sensors in each docking unit (104), thus ensuring that the swappable batteries (102) are maintained within optimal thermal conditions. Such an integration significantly enhances the safety and efficiency of the charging process by preventing overheating, which can lead to battery degradation or failure. Further, by actively managing the thermal environment of the swappable batteries (102), the system (100) extends the operational life and maintains the efficiency of the swappable batteries (102), pre-setly in conditions where thermal management is critical to preventing damage. In an exemplary operating scenario, during a summer peak load period where the ambient temperatures rise significantly, the thermal load on the swappable batteries (102) is increased during charging. The cooling arrangement, managed by the control arrangement (106), activates additional cooling measures to counteract the heat build-up. Such an operation can comprise, for example, increasing airflow, enhancing coolant circulation, or adjusting the charging rates to reduce thermal stress. Such proactive thermal management ensures that each swappable battery (102) is charged within its thermal tolerance limits, thus safeguarding battery health and performance during extreme conditions. Optionally, the cooling arrangement utilize phase change materials (PCMs) that absorb heat when the battery temperature rises, thereby passively controlling the temperature without the need for active cooling systems.
[00052] In another embodiment, the battery charging system (100) comprises a central power storage component. The electric current is supplied from the first set to the central power storage component and central power storage component to the second set. The central power storage component acts as an intermediary storage solution that receives electric current from the first set of swappable batteries (102) with lower SoC and then redistributes the electric current to the second set of swappable batteries (102) with higher SoC. The inclusion of the central power storage component allows for a more controlled and stable distribution of electric current within the system (100), enhancing the efficiency of power management. Such a setup ensures that energy is not wasted but rather stored and used effectively, maximizing the utility of the electric current generated or received by the system (100). Additionally, the central power storage component serves as a buffer, mitigating any sudden fluctuations in power demand or supply, thereby stabilizing the operational dynamics of the battery charging system (100). During operation, when there is a high demand for electric vehicles in the morning when many vehicles need fully charged batteries, the central power storage component collects and stores electric current from the power supply grid (108) during off-peak hours at night when electricity rates are lower. Subsequently, the power storage component distributes the stored energy to the swappable batteries (102) in the morning, ensuring that there is sufficient power available to meet the demand without overloading the grid (108) or incurring high energy costs. Thus, the present disclosure enhances the energy efficiency of the system (100) and ensures that electric vehicles have access to fully charged batteries exactly when needed, demonstrating the capability of the system (100) to adapt to usage patterns and energy pricing dynamically. Optionally, the central power storage component exports excess energy to the power supply grid (108) or other external systems, such as stationary energy storage solutions or backup power systems, making the system (108) versatile in broader energy management scenarios.
[00053] The battery charging system (100) provides an integrated solution for managing the charging process of swappable batteries (102) in electric vehicles, optimizing the utilization of available electrical infrastructure. By interacting with multiple docking units (104), the battery charging system (100) ensures that batteries with varied states of charge are efficiently charged, promoting a balanced usage of energy resources. The battery charging system (100) improves operational efficiency by automating the management of power distribution based on the state of charge, which minimizes the need for manual intervention and reduces operational downtime for electric vehicles awaiting fully charged batteries.
[00054] In an embodiment, each docking unit (104) individually determining the state of charge (SoC) of the swappable battery (102) allows for monitoring and targeted charging strategies, leading to improved battery life and performance. Such capability enables each docking unit (104) to customize the charging process based on the specific needs of each battery, which prevents overcharging and undercharging scenarios. By allowing each docking unit (104) to receive a swappable battery (102), the system enhances flexibility in handling a diverse range of battery types and capacities, thus accommodating various electric vehicle models without the need for separate charging setups.
[00055] In an embodiment, the control arrangement (106) dynamically adjusts the power supply by connecting to each docking unit (104), which facilitates an adaptive response to changes in grid (108) conditions and battery requirements. This response capability prevents potential damage to batteries due to inappropriate charging levels and helps maintain the stability of the power grid. Through the determination of a loss of supply from the power supply grid (108), the control arrangement (106) ensures continuous operation of the charging system by switching to alternative power sources or adjusting the charging rates, thus maintaining the reliability of the service even during grid failures.
[00056] In another embodiment, the control arrangement (106) with the power supply grid (108) allows for the harnessing of electricity from grind (108) to charge electric vehicles efficiently, making use of off-peak tariffs and renewable energy sources whenever available. This strategic utilization of grid power can lead to cost savings and reduced environmental impact. The power supply grid (108) supports the system’s ability to draw on a robust energy network, enhancing the system’s capability to provide uninterrupted service to a large number of electric vehicles, which is critical in high-demand scenarios. Further, identification and utilization of the first set of swappable batteries (102) with a SoC lower than a preset threshold for supplying power to other batteries enables efficient approach to energy management, where undercharged batteries are use as power source to charge other batteries such that batteries are charged at possible maximum charge levels for immediate deployment. This method reduces waiting times for vehicles that need fully charged batteries quickly, enhancing the overall efficiency of fleet operations.
[00057] In another embodiment, the battery charging system (100) allows for dynamic tariff management through the control arrangement (106), which monitors current electric tariffs. If the tariff exceeds a set threshold, the control arrangement (106) disconnects the power supply grid (108) from each swappable battery (102) to prevent charging during high-tariff periods. This feature reduces operational costs by avoiding electricity usage when costs are highest. Additionally, the control arrangement (106) facilitates the redistribution of electric current from the first set of swappable batteries (102) to the second set when tariffs are elevated, ensuring optimal usage of stored energy and maintaining battery charge levels without additional power consumption from grid (108).
[00058] The control arrangement (106) coordinates with these relays to selectively connect or disconnect the power supply grid (108) from each swappable battery (102). This segregation allows for targeted charging or discharging of batteries based on real-time power requirements and condition of grid (108), thereby enhancing the efficiency of power management within the system (100). The mechanical relay, controlled by the control arrangement (106), also enables the transfer of electric current from the first set of swappable batteries to the second set, thus supporting continuous energy supply even during grid outages. This system element provides an uninterrupted power supply, increasing the reliability and operational uptime of the system.
[00059] In an embodiment, the bidirectional converters facilitate the adjustment of voltage levels between the first and second sets of swappable batteries (102) to enable compatibility between different battery groups and optimizes the power transfer process, thus safeguarding battery health and enhancing the overall efficiency of the charging system. Actuators within each docking unit (104), specifically electric linear actuators, provide physical manipulation of electrical connections. These actuators enable or disable connections to the power supply grid (108) and between battery sets. This physical control mechanism facilitates rapid response to changes in power demand or supply conditions, enhancing the adaptability and responsiveness of the charging system to external changes.
[00060] In an embodiment, temperature sensor enables precise monitoring of the temperature of the corresponding swappable battery (102) to enable adjustment of electric current supplied to each swappable battery (102) based on its specific temperature condition. Such regulation of electric current enhances the safety of the battery charging system by reducing the risk of thermal runaway in the swappable batteries (102). Moreover, the adjustment of electric current depending on the temperature contributes to optimizing the charging cycle, which in turn extends the lifespan of the swappable batteries (102). Additionally, the ability to monitor and adjust for temperature variations ensures consistent performance across all batteries, leading to improved reliability of the battery charging system (100). Further, cooling arrangement enables active management of the temperature of each swappable battery (102). By actively controlling the cooling based on real-time temperature data, the battery charging system (100) prevents overheating, thereby safeguarding against potential damage from excessive heat.
[00061] In an embodiment, the system (100) can utilize sensing arrangement for each of docking units (104), wherein the sensing arrangement can comprise various sensors for measurement of various battery parameters. For determining the charge level of each battery, voltage sensors can be utilized, wherein the voltage sensor enable measurement of voltage across the battery terminals to infer the state of charge (SoC). To assess the health of each battery, impedance sensor can be employed to analyze the internal resistance of the battery, providing insights into its overall health and efficiency. For tracking the charge/discharge cycles, a combination of current sensors and an integrated battery management system (BMS) records and calculates the number of cycles each battery undergoes. For measurement of energy density or capacity of each battery, coulomb counters can be used to measure the total charge that moves in and out of the battery, which, when combined with voltage measurements, provides an accurate estimate of energy density. To sense energy storage capacity, a combination of coulomb counters and specific energy sensors, which evaluate the energy capacity per unit mass or volume, is used. To measure the maximum charging current handling capability of each battery (102), high-precision current sensors can be implemented to monitor the maximum current (102) battery can safely handle during charging.
[00062] Fig. 2 illustrates an exemplary flow diagram about operational procedure of a charging system for swappable batteries (102) used in electric vehicles, in accordance with embodiment of present disclosure. The process begins by determining the state of charge (SoC) of the batteries (102) to assess current energy levels thereof. Following the SoC assessment, the control arrangement (106) evaluates the status of the power supply from the grid. If the power supply from the grid (108) is stable and uninterrupted, the control arrangement (106) enables charging of each battery (102) using energy of power grid. However, if there is a loss of power from the grid, the control arrangement (106) takes an alternative course of action. The control arrangement (106) categorizes the batteries (102) into two sets based on their SoC levels. The batteries (102) with a SoC above the preset threshold are grouped into the second set, indicating they have higher energy reserves. Conversely, the batteries (102) with a SoC below the threshold are placed in the first set, indicating lower energy reserves. After categorization, the control arrangement (106) activates a contingency plan where the batteries (102) from the first set (lower SoC) are used to enable the charging of the batteries (102) in the second set (higher SoC). This redistribution of power helps maintain continuous charging operations and to provide maximum number of batteries (102) with maximum charge level. Thus, the present disclosure enables charging station can operate effectively by utilizing the stored energy within the batteries (102) to maintain a seamless supply of charged batteries (102) for electric vehicles.
[00063] Fig. 3 shows a flow diagram to present the operational procedure of a battery charging system for electric vehicles, particularly focusing on how charging station adapts to various power supply conditions to maintain efficient charging. The control arrangement (106) activates sensing apparatus to measure SoC of each battery (102) received within docking units (104). Following the SoC assessment, the control arrangement (106) checks for any power loss from the grid (108). If there is a power loss, the control arrangement (106) activates emergency protocol. The control arrangement (106) categorizes all batteries (102) into two sets: those above a predefined SoC threshold (i.e., second set) and those below (i.e., first set). If the power cut is existed, the control arrangement (106) leverages the stored energy from the batteries (102) of first category to charge batteries (102) of second category to enabling continuous operation without relying on the grid energy. If there is no power loss, the control arrangement (106) monitors the electric tariff, a critical cost-control measure. Tariff monitoring allows the control arrangement (106) to optimize charging costs, which can vary significantly during the day or night. If the monitored tariff is above a certain cost threshold, the control arrangement (106) concludes that charging based on grid energy would be economically expensive due to high costs. In such a scenario, the control arrangement (106) disconnects grid supply and, similar to the power loss scenario, will rely on the internal redistribution of power from batteries (102) of first category to charge the batteries (102) of second category to optimize charging costs. Conversely, if the tariff is not above the threshold, the control arrangement (106) continues to charge the batteries normally using grid power, taking advantage of lower-cost electricity. Thus, terrif based charging energy source selection decision enables that the charging operations are cost-effective, maintaining the system's efficiency and reducing operational expenses. Thus, the present disclosure provides adaptive approach to managing power supply and costs via real-time tariff monitoring and strategic power redistribution ensures that the battery charging station operates optimally, balancing energy use with cost efficiency and system reliability. Such smart energy management practices are essential in the context of fluctuating energy prices and varying grid stability, ensuring that the charging infrastructure for electric vehicles is both sustainable and economically viable.
[00064] Example embodiments herein have been described above with reference to block diagrams and flowchart illustrations of methods and apparatuses. It will be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by various means including hardware, software, firmware, and a combination thereof. For example, in one embodiment, each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations can be implemented by computer program instructions. These computer program instructions may be loaded onto a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions which execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
[00065] Throughout the present disclosure, the term ‘processing means’ or ‘microprocessor’ or ‘processor’ or ‘processors’ includes, but is not limited to, a general purpose processor (such as, for example, a complex instruction set computing (CISC) microprocessor, a reduced instruction set computing (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, a microprocessor implementing other types of instruction sets, or a microprocessor implementing a combination of types of instruction sets) or a specialized processor (such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), or a network processor).
[00066] The term “non-transitory storage device” or “storage” or “memory,” as used herein relates to a random-access memory, read only memory and variants thereof, in which a computer can store data or software for any duration.
[00067] Operations in accordance with a variety of aspects of the disclosure is described above would not have to be performed in the precise order described. Rather, various steps can be handled in reverse order or simultaneously or not at all.
[00068] While several implementations have been described and illustrated herein, a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein may be utilized, and each of such variations and/or modifications is deemed to be within the scope of the implementations described herein. More generally, all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific implementations described herein. It is, therefore, to be understood that the foregoing implementations are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, implementations may be practiced otherwise than as specifically described and claimed. Implementations of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

1. A battery charging system (100) for charging swappable batteries (102) of electric vehicles, the system (100) comprising:
- multiple docking units (104), wherein each docking unit (104) receives a swappable battery (102) and wherein each docking unit (104) determines a state of charge (SoC) of the swappable battery (102) received within the corresponding docking unit (104);
- a control arrangement (106) connected to each docking unit (104), wherein the control arrangement (106) enables supply of electric current from a power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) to charge the corresponding swappable battery (102) and wherein the control arrangement (106):
- determines loss of supply of electric current from the power supply grid (108);
- identifies:
- a first set of the swappable batteries (102) having the SoC lower than a pre-set threshold; and
- a second set of the swappable batteries (102) having the SoC higher than the pre-set threshold; and
- causes supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102) to enable charging of each swappable battery (102) of the second set.
2. The battery charging system (100) as claimed in claim 1, wherein the control arrangement (106) monitors a present electric tariff and disconnects the supply of electric current from the power supply grid (108) to each swappable battery (102), if the present electric tariff is higher than a predetermined tariff, and wherein the control arrangement (106) causes the supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102), if the present electric tariff is higher than the predetermined tariff.
3. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a mechanical relay to disconnect the supply of electric current between the power supply grid (108) and each swappable battery (102) and wherein the control arrangement (106) is connected to each mechanical relay to manage the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid (108).
4. The battery charging system (100) as claimed in claim 3, wherein the control arrangement (106) controls each mechanical relay to enable the supply of electric current from the first set to the second set.
5. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a bidirectional converter to manage the supply of electric current from the first set to the second set, and wherein the bidirectional converter adjusts voltage levels between the first set and the second set.
6. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a sensor to determine the SoC of the swappable battery (102) received within the corresponding docking unit (104) and wherein each sensor is connected to the control arrangement (106).
7. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises an actuator to:
- physically disconnect an electrical connection between the power supply grid (108) and the corresponding docking unit (104); and
- physically connect the first set and the second set,
- wherein each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit (104).
8. The battery charging system (100) as claimed in claim 1, wherein the system (100) comprises a temperature sensor within each docking unit (104) to monitor a temperature of the corresponding swappable battery (102) received therein and wherein the control arrangement (106) adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature.
9. The battery charging system (100) as claimed in claim 8, wherein the system (100) comprises a cooling arrangement connected to the control arrangement (106) and wherein the control arrangement (106) controls the cooling arrangement to manage the monitored temperature of each swappable battery (102) to preventing overheating.
10. The battery charging system (100) as claimed in claim 1, wherein the battery charging system (100) comprises a central power storage component and wherein the electric current is supplied from the:
- first set to the central power storage component; and
- central power storage component to the second set.
11. The system as claimed in claim 1, wherein the control arrangement (106) dynamically adjusts the pre-set threshold based on at least one parameter selected from statistical distribution of battery charge levels of each battery, a health of each battery, charge/discharge cycles of each battery, a voltage level of each battery, and an energy density or capacity of each battery.
12. The system as claimed in claim 1, wherein the control arrangement (106) prioritizes one battery from the second set-based parameters selected from critical requirement, a pre-booking status, an energy storage capacity, and a maximum charging current handling capability.

Abstract
BATTERY CHARGING SYSTEM FOR CHARGING SWAPPABLE BATTERIES OF ELECTRIC VEHICLES

The present disclosure provides a battery charging system for charging swappable batteries of electric vehicles. The system comprises multiple docking units, wherein each docking unit receives a swappable battery and determines a state of charge (SoC) of the swappable battery received within. A control arrangement is connected to each docking unit, which enables supply of electric current from a power supply grid to each swappable battery. The control arrangement determines loss of supply of electric current from the power supply grid, identifies a first set of the swappable batteries having the SoC lower than a pre-set threshold, identifies a second set of the swappable batteries having the SoC higher than the pre-set threshold and causes supply of electric current from the first set of swappable batteries to the second set of swappable batteries to enable the SoC of each swappable battery of the second set to charge to 100% SoC.

, Claims:1. A battery charging system (100) for charging swappable batteries (102) of electric vehicles, the system (100) comprising:
- multiple docking units (104), wherein each docking unit (104) receives a swappable battery (102) and wherein each docking unit (104) determines a state of charge (SoC) of the swappable battery (102) received within the corresponding docking unit (104);
- a control arrangement (106) connected to each docking unit (104), wherein the control arrangement (106) enables supply of electric current from a power supply grid (108) to each swappable battery (102) received within the multiple docking units (104) to charge the corresponding swappable battery (102) and wherein the control arrangement (106):
- determines loss of supply of electric current from the power supply grid (108);
- identifies:
- a first set of the swappable batteries (102) having the SoC lower than a pre-set threshold; and
- a second set of the swappable batteries (102) having the SoC higher than the pre-set threshold; and
- causes supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102) to enable charging of each swappable battery (102) of the second set.
2. The battery charging system (100) as claimed in claim 1, wherein the control arrangement (106) monitors a present electric tariff and disconnects the supply of electric current from the power supply grid (108) to each swappable battery (102), if the present electric tariff is higher than a predetermined tariff, and wherein the control arrangement (106) causes the supply of electric current from the first set of swappable batteries (102) to the second set of swappable batteries (102), if the present electric tariff is higher than the predetermined tariff.
3. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a mechanical relay to disconnect the supply of electric current between the power supply grid (108) and each swappable battery (102) and wherein the control arrangement (106) is connected to each mechanical relay to manage the supply of electric current from the first set to the second set based on the determined loss of supply of electric current from the power supply grid (108).
4. The battery charging system (100) as claimed in claim 3, wherein the control arrangement (106) controls each mechanical relay to enable the supply of electric current from the first set to the second set.
5. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a bidirectional converter to manage the supply of electric current from the first set to the second set, and wherein the bidirectional converter adjusts voltage levels between the first set and the second set.
6. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises a sensor to determine the SoC of the swappable battery (102) received within the corresponding docking unit (104) and wherein each sensor is connected to the control arrangement (106).
7. The battery charging system (100) as claimed in claim 1, wherein each docking unit (104) comprises an actuator to:
- physically disconnect an electrical connection between the power supply grid (108) and the corresponding docking unit (104); and
- physically connect the first set and the second set,
- wherein each actuator is an electric linear actuator to move electrical connectors within the corresponding docking unit (104).
8. The battery charging system (100) as claimed in claim 1, wherein the system (100) comprises a temperature sensor within each docking unit (104) to monitor a temperature of the corresponding swappable battery (102) received therein and wherein the control arrangement (106) adjusts the supply of electric current to the corresponding swappable battery (102) based on the monitored temperature.
9. The battery charging system (100) as claimed in claim 8, wherein the system (100) comprises a cooling arrangement connected to the control arrangement (106) and wherein the control arrangement (106) controls the cooling arrangement to manage the monitored temperature of each swappable battery (102) to preventing overheating.
10. The battery charging system (100) as claimed in claim 1, wherein the battery charging system (100) comprises a central power storage component and wherein the electric current is supplied from the:
- first set to the central power storage component; and
- central power storage component to the second set.
11. The system as claimed in claim 1, wherein the control arrangement (106) dynamically adjusts the pre-set threshold based on at least one parameter selected from statistical distribution of battery charge levels of each battery, a health of each battery, charge/discharge cycles of each battery, a voltage level of each battery, and an energy density or capacity of each battery.
12. The system as claimed in claim 1, wherein the control arrangement (106) prioritizes one battery from the second set-based parameters selected from critical requirement, a pre-booking status, an energy storage capacity, and a maximum charging current handling capability.