DESC:SYSTEM FOR CHARGING BATTERIES AT BATTERY SWAPPING STATION
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202221069381 filed on 01/12/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a system for charging batteries. The present disclosure particularly relates to a system for charging batteries at a battery swapping station.
BACKGROUND
Recently, there has been a rapid development in electric vehicles because of their ability to resolve pollution-related problems and serve as a clean mode of transportation. Generally, electric vehicles include a battery pack, power pack, and/or combination of electric cells for storing electricity required for the propulsion of the vehicles. The electrical power stored in the battery pack of the electric vehicle is supplied to the traction motor for moving the electric vehicle. Once the electrical power stored in the battery pack of the electric vehicle depletes, the battery pack is required to be charged from a power source by connecting the electric vehicle with a charger.
Generally, the electric vehicles comprise non-removable battery which is required to be charged by connecting a charger to the electric vehicle. However, such arrangement suffers from multiple drawbacks such as overlong charging time required, anxiety mileage of the user, inconvenience in charging, unavailability of charging infrastructure and so forth.
To overcome the above issues, the swappable battery packs are gaining popularity as it solves the problem of long charging times and range anxiety. The user can swap a discharged battery with a fully charged one at a battery swapping station.
However, the existing battery swapping stations are not efficient to handle simultaneous charging of multiple batteries. Furthermore, the existing battery swapping stations are complex in nature leading to decreased robustness. Furthermore, the complexity of the existing battery swapping stations increases the chances of fault occurrence. Furthermore, the existing battery swapping stations are required to be completely shut in case of occurrence of any fault anywhere in the station. Furthermore, the existing battery swapping stations are difficult to maintain and repair due to their complex design. Moreover, the existing battery swapping stations are not feasible in the remote areas with low or no availability of electricity from AC grid. Moreover, the existing battery swapping stations increase load on the electricity grid and may cause grid failure.
Therefore, there exists a need for an improved system for charging battery packs at the battery swapping station and overcome one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a system for charging batteries at a battery swapping station.
Another object of the present disclosure is to provide a system for charging batteries at a battery swapping station with power sharing between the batteries.
In accordance with the first aspect of the present disclosure, there is provided a system for charging batteries at a battery swapping station. The system comprises a plurality of charging bins for receiving a plurality of batteries, a plurality of active bridge modules, wherein each active bridge module is connected to at least one charging bin of the plurality of charging bins, a high frequency transformer comprising a plurality of primary windings and a plurality of secondary windings, wherein each of the secondary winding is connected to one active bridge module of the plurality of active bridge modules, characterized in that the plurality of active bridge modules are configured to exchange power therebetween through the plurality of secondary windings for charging at least one battery of the plurality of batteries in the plurality of charging bins.
The present disclosure provides a system for charging batteries at a battery swapping station. Beneficially, the system of the present enables cross-charging between the plurality of batteries. Beneficially, the system of the present disclosure is not dependent on availability of grid for charging of the batteries in the swapping station. Beneficially, the system as disclosed in the present disclosure is simple in design and eliminates the need for complex architectures. Beneficially, the system of the present disclosure is highly efficient and simultaneously charges a plurality of batteries with minimal power losses. Beneficially, the system of the present disclosure is highly robust. Beneficially, the system of the present disclosure is easier to maintain due to simpler design. Moreover, the system of the present disclosure is advantageous in terms of improved fault protection. Beneficially, the system of the present disclosure is modular, thus, the whole system is not required to be shut in case of occurrence of any fault. Beneficially, the system of the present disclosure is capable of isolating any faulty module, to protect rest of the system from the fault.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a block diagram of a system for charging batteries at a battery swapping station, when grid is not available, in accordance with an aspect of the present disclosure.
Figure 2 illustrates a block diagram of a system for charging batteries at a battery swapping station, when grid is available, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a system for charging batteries at a battery swapping station and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “power source” “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery cells connected to provide a higher combined voltage or capacity than what a single battery can offer. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery packs, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of cell arrays which in turn comprises a plurality of battery cells.
As used herein, the term “front-end converter” refers to a device that converts alternating current (AC) to direct current (DC). The front-end converter converts the high-voltage AC power from the grid to the DC power. Preferably, the front-end converter is a switching converter that uses semiconductor switches to convert the AC to DC. Beneficially, the AC-DC converter is more efficient than conventional linear converters.
As used herein, the term “active bridge module” refers to a device that converts direct current (DC) from one voltage level to another. Preferably, the active bridge module is a switching converter that offers the best combination of efficiency, cost, and performance.
As used herein, the terms “switching legs”, “inverter legs”, and “phase legs” are used interchangeably and refer to individual circuit legs of inverter which are responsible for converting the AC power into DC power or vice-versa. It is to be understood that the switching legs are designed based on the configuration of the converter. It is to be understood that the switching legs comprise a pair of switches.
As used herein, the term “high frequency transformer” refers to a transformer that operates at a higher frequency than a traditional transformer and efficiently converts high frequency AC power. Beneficially, the high frequency transformer is small in size and lightweight compared to a traditional transformer.
As used herein, the term “AC grid” refers to an AC power supply received from the grid. The AC grid may be a high voltage three-phase AC grid.
As used herein, the terms “high voltage DC link” and “high voltage DC link capacitor” are used interchangeably and refer to a capacitor that is used to smooth out the fluctuating DC voltage coming from a converter. The DC link capacitor functions to smooth out the power between the two components, stabilize the DC voltage, and act as energy storage for transient loads.
As used herein, the term “switches” and “plurality of switch” are used interchangeably and refers to power electronics devices that control the flow of electrical current. The switches are responsible for converting the DC power to AC or AC power to DC power or DC power to another DC power. The switches may be at least one of MOSFETs, IGBTs, transistors, or a combination thereof.
As used herein, the term “primary converter” refers to a power converter that produces high power output for charging the plurality of batteries in the battery swapping station.
As used herein, the term “secondary converter” refers to a power converter that produces low power output for charging the plurality of batteries in the battery swapping station.
As used herein, the term “bypass switch” refers to a switching device configured to electrically disconnect the battery in the charging bin.
As used herein, the terms “control unit”, “microcontroller” and ‘processor’ are used interchangeably and refer to a computational element that is operable to respond to and process instructions that operationalize the system for charging batteries. Optionally, the control unit may be a micro-controller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing unit. Furthermore, the term “processor” may refer to one or more individual processors, processing devices, and various elements associated with a processing device that may be shared by other processing devices. Furthermore, the control unit comprises a software module residing in the control unit and executed by the microcontroller to control the operation of the active bridge modules of the system for charging batteries. It is to be understood that the software module may comprise algorithms and control instructions to control the operation of the active bridge modules of the system for charging batteries.
Figure 1, in accordance with an embodiment, describes a system 100 for charging batteries at a battery swapping station. The system comprises a plurality of charging bins 102 for receiving a plurality of batteries, a plurality of active bridge modules 104, wherein each active bridge module 104 is connected to at least one charging bin 102 of the plurality of charging bins 102, a high frequency transformer 106 comprising a plurality of primary windings 108 and a plurality of secondary windings 110, wherein each of the secondary winding 110 is connected to one active bridge module 104 of the plurality of active bridge modules 104, characterized in that the plurality of active bridge modules 104 are configured to exchange power therebetween through the plurality of secondary windings 110 for charging at least one battery of the plurality of batteries in the plurality of charging bins 102.
The present disclosure provides the system 100 for charging batteries at a battery swapping station. Beneficially, the system 100 of the present enables cross-charging between the plurality of batteries. Beneficially, the system 100 of the present disclosure is not dependent on availability of grid for charging of the batteries in the swapping station. Beneficially, during the non-availability of grid, the charging bins 102 of the system 100 can be filled with fully charge batteries transported from other places to the system 100. As users would keep on removing fully charged batteries and insert their discharged or partially discharged batteries, the system 100 would keep at least one battery fully charged by transferring power from other lower charged batteries. Beneficially, the system 100 as disclosed in the present disclosure is simple in design and eliminates the need for complex architectures. Beneficially, the system 100 of the present disclosure is highly efficient and simultaneously charges a plurality of batteries with minimal power losses. Beneficially, the system 100 of the present disclosure is highly robust. Beneficially, the system 100 of the present disclosure is easier to maintain due to simpler design. Moreover, the system 100 of the present disclosure is advantageous in terms of improved fault protection. Beneficially, the system 100 of the present disclosure is modular, thus, the whole system 100 is not required to be shut in case of occurrence of any fault. Beneficially, the system 100 of the present disclosure is capable of isolating any faulty module, to protect rest of the components from the fault.
In an embodiment, each of the charging bin 102 comprises a locking mechanism to securely lock the received battery. Beneficially, the locking mechanism secures the battery inside the charging bin 102 to physically protect the battery from theft or misuse. Furthermore, the locking mechanism ensures stable mechanical connection between terminals of the battery and the terminals of the charging bin 102 to ensure safety of the battery during the charging process.
In an embodiment, each of the charging bin 102 is connected to the active bridge module 104 via a bypass switch 112, wherein the bypass switch 112 is configured to electrically disconnect the charging bin 102 from the active bridge module 104 once the received battery is fully charged. Beneficially, the bypass switch 112 electrically isolates the battery from the active bridge module 104 and the charging bin 102 to protect the battery in case of any fault. Furthermore, the bypass switch 112 ensures overcharging protection of the battery in the charging bin 102.
In an embodiment, each of the active bridge module 104 is configured to regulate a power supplied to the plurality of charging bins 102 for charging the plurality of received batteries. It is to be understood that the active bridge module 104 comprises two pairs of switching devices in bridge configuration. Beneficially, the active bridge module 104 regulates the power supplied to the plurality of charging bins 102 for charging the plurality of received batteries to ensure efficient and optimal performance of the system 100. It is to be understood that each of the active bridge module 104 is configured to regulate a power exchanged between the plurality of charging bins 102 for charging the plurality of received batteries. Furthermore, the active bridge module 104 regulates the power supplied to the plurality of charging bins 102 for charging the plurality of received batteries to ensure the safety of the battery from faults such as over voltage and/or over current, during the charging process of the battery in the charging bin 102. Beneficially, the power supply is regulated by adjusting the phase shift among the active bridge modules 104 and duty cycle control.
In an embodiment, the plurality of secondary windings 110 of the high frequency transformer 106 provide galvanic isolation between the plurality of active bridge modules 104. Beneficially, the combination of the active bridge modules 104 and the secondary windings 110 acts as a dual active bridge. Beneficially, the dual active bridge configuration enables galvanic isolation while enabling exchange of power between the plurality of active bridge modules 104.
Figure 2, in accordance with an embodiment, describes the system 100 during the availability of an AC grid 116. The system 100 comprises a front-end converter 118, a primary converter 120 and a secondary converter 122 to connect the plurality of primary windings 108 of the high frequency transformer 106 with an AC grid 116.
The front-end converter 118 comprises three pairs of switching devices in inverter phase leg configuration. The pair of switching devices in each inverter phase leg switch alternatively to convert the AC input into high voltage DC stage.
In an embodiment, the system 100 comprises a high voltage direct current link 114. Beneficially, the high voltage direct current link 114 stabilize the fluctuating voltages between the components of the system 100.
In an embodiment, the front-end converter 118 is configured to convert power received from the AC grid 116 into high voltage DC stage power. In an embodiment, the front-end converter 118 improves power quality by removing harmonic distortion from the power received from the AC grid 116. In an embodiment, the front-end converter 118 achieves unity power factor during operation. Beneficially, the front-end converter 118 improves efficiency and reduce losses in the system 100.
In an embodiment, the primary converter 120 is configured to convert the high voltage DC stage power into the high frequency transformer 106 input when large amount of power is required to charge the plurality of batteries. Beneficially, the primary converter 120 is operationalized when the large amount of power is required to charge the battery. The primary converter 120 beneficially enables faster charging of the battery by supplying large amount of power to charge the plurality of batteries.
In an embodiment, the secondary converter 122 is configured to convert the high voltage DC stage power into the high frequency transformer 106 input when small amount of power is required to charge the plurality of batteries. Beneficially, the secondary converter 122 is operationalized when the small amount of power is required to charge the battery. The secondary converter 122 beneficially enables slower charging of the battery by supplying small amount of power to charge the plurality of batteries.
In an embodiment, the system 100 comprises a control unit configured to identify a state of charge of each of the plurality of batteries, electrically disconnect the charging bin 102 with fully charged battery from the active bridge module, and instruct the active bridge module 104 to transfer power from at least one battery to other battery until the other battery is fully charged or start the primary converter 120 and the secondary converter 122 to charge the plurality of batteries from the power received from the AC grid 116.
In an exemplary embodiment, when the AC grid 116 is not available, the system 100 charges at least one battery by enabling exchange of power between the active bridge modules 104. In another exemplary embodiment, when the AC grid 116 is available, the system 100 charges the plurality of batteries using the power received from the AC grid 116.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

,CLAIMS:WE CLAIM:
1. A system (100) for charging batteries at a battery swapping station, the system comprises:
- a plurality of charging bins (102) for receiving a plurality of batteries;
- a plurality of active bridge modules (104), wherein each active bridge module (104) is connected to at least one charging bin (102) of the plurality of charging bins (102); and
- a high frequency transformer (106) comprising a plurality of primary windings (108) and a plurality of secondary windings (110), wherein each of the secondary winding (110) is connected to one active bridge module (104) of the plurality of active bridge modules (104),
characterized in that the plurality of active bridge modules (104) are configured to exchange power therebetween through the plurality of secondary windings (110) for charging at least one battery of the plurality of batteries in the plurality of charging bins (102).
2. The system (100) as claimed in claim 1, wherein each of the charging bin (102) comprises locking mechanism to securely lock the received battery.
3. The system (100) as claimed in claim 1, wherein each of the charging bin (102) is connected to the active bridge module (104) via a bypass switch (112), wherein the bypass switch (112) is configured to electrically disconnect the charging bin (102) from the active bridge module (104) once the received battery is fully charged.
4. The system (100) as claimed in claim 1, wherein each of the active bridge module (104) is configured to regulate a power supplied to the plurality of charging bins (102) for charging the plurality of received batteries.
5. The system (100) as claimed in claim 1, wherein the plurality of secondary windings (110) of the high frequency transformer (106) provide galvanic isolation between the plurality of active bridge modules (104).
6. The system (100) as claimed in claim 1, wherein the system (100) comprises a front-end converter (118), a primary converter (120) and a secondary converter (122) to connect the plurality of primary windings (108) of the high frequency transformer (106) with an AC grid (116).
7. The system (100) as claimed in claim 6, wherein the system (100) comprises a high voltage direct current link (114).
8. The system (100) as claimed in claim 6, wherein the front-end converter (118) is configured to convert power received from the AC grid (116) into high voltage DC stage power.
9. The system (100) as claimed in claim 6, wherein the front-end converter (118) improves power quality by removing harmonic distortion from the power received from the AC grid (116).
10. The system (100) as claimed in claim 6, wherein the primary converter (120) is configured to convert the high voltage DC stage power into the high frequency transformer (106) input when large amount of power is required to charge the plurality of batteries.
11. The system (100) as claimed in claim 6, wherein the secondary converter (122) is configured to convert the high voltage DC stage power into the high frequency transformer (106) input when small amount of power is required to charge the plurality of batteries.
12. The system (100) as claimed in claim 1, wherein the system (100) comprises a control unit configured to:
- identify a state of charge of each of the plurality of batteries;
- electrically disconnect the charging bin (102) with fully charged battery from the active bridge module; and
- instruct the active bridge module (104) to transfer power from at least one battery to other battery until the other battery is fully charged or start the primary converter (120) and the secondary converter (122) to charge the plurality of batteries from the power received from the AC grid (116).