Compact and modular electrical power supply unit, with multi-converters, notably for fast recharging terminals for electric vehicles

• US 20150180252A1
• Filed: 12/22/2014
• Published: 06/25/2015
• Est. Priority Date: 12/23/2013
• Status: Active Grant

• Current Assignee: EVTRONIC
• Original Assignee: EVTRONIC
• Inventors: STEMPIN, Eric, DUPONCHEEL, Romain
• Granted Patent: US 9,590,434 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/31 Charging columns specially adapted for electric vehicles
• CPC Class Codes: B60L 53/53 Batteries
• CPC Class Codes: B60L 53/63 in response to network capacity
• CPC Class Codes: H02J 1/10 Parallel operation of dc sources
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 7/219 in a bridge configuration
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y04S 10/126 the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]

Abstract

The device includes a set of electronic switches having a common structure and forming modules for converting electrical energy and a power DC bus onto which the modules are connected in parallel. These modules are controlled by a control circuit so as to supply electrical energy originating from external sources of energy over the power DC bus or to extract electrical energy over this bus to recharge batteries. The device includes at least one AC-DC conversion module configured for carrying out the rectification of an AC line supply and for powering the DC bus, a DC-DC conversion module configured for charging a user battery from the DC bus and a DC-DC conversion module configured for alternatively allowing the recharging of a storage battery from the DC bus or the discharge of the same battery over the latter. The various modules are mounted onto an accommodation structure forming a heat dissipator.

Claims

1. A modular device (11) for conversion of electrical energy for implementing the recharging of an electrical battery (58), or user battery, using an AC line supply (61) and supplementary sources of electrical energy (59), characterized in that it comprises:

a plurality of switching modules (122a, 122b, 122c, 13, 14), with a substantially identical structure, each switching module being associated with one of the available sources of electrical energy (61, 59) and producing, by chopping the voltage delivered by the source with which a DC voltage of given value is associated;

a power DC bus comprising two electrical lines (23, 24), to which each of the various available sources of electrical energy is connected by means of the switching module which is associated with it, each switching module being composed of two electronic switches configured in series between the two lines (23, 24) of the power DC bus,

a control circuit (22) which generates the chopping controls applied to the switches of the various switching modules (122a, 122b, 122c, 13, 14), the chopping control applied to a given switching module being defined by a control law which depends on the voltage and on the charge current (53) necessary for performing a recharging of the electrical battery in question (58) and on the maximum power (51) available from the AC line supply (61);

an accommodation structure (31) configured for receiving the various switching modules and forming the power DC bus, said accommodation structure comprising a plurality of functionally identical locations onto which the various switching modules can be placed.

2. The device as claimed in claim 1, characterized in that the chopping controls generated by the control circuit are square-wave signals having a duty cycle which varies as a function of the value of the voltage (52) to be established on the power DC bus.

3. The device as claimed in claim 1, characterized in that, since the said AC line supply (61) is a three-phase supply, it comprises three switching modules (122a, 122b, 122c) each carrying out the rectification of the AC voltage delivered by one of the phases into a DC voltage;

the mid-point of each of the three switching modules being connected to one phase of the AC supply (61) via a transformer (121).

4. The device as claimed in claim 1, characterized in that it comprises a switching module (13) configured for implementing the connection of an electrical energy storage battery (59), of given voltage, to the power DC bus, in such a manner that the storage battery (59) can be charged via the power DC bus or else discharged into the latter.

5. The device as claimed in claim 1, characterized in that it comprises a switching module (14) configured for making the connection of a user battery (58), of a given voltage, to the power DC bus, in such a manner that said user battery (58) can be charged up by the power DC bus with a given voltage and charging current, both characteristic of the battery used.

6. The device as claimed in claim 5, characterized in that the switching module (14) is furthermore configured in such a manner that said user battery (58) can be discharged onto the power DC bus so as to supply a top-up electrical energy over this bus.

7. The device as claimed in claim 1, characterized in that it comprises an accommodation structure (11) which houses a set of switching modules, with identical structures, mounted onto the accommodation structure (31) so as to form at least three stages for conversion of electrical energy (12, 13 and 14):

a reversible AC-DC converter stage (12) comprising three switches (122a, 122b, 122c) respectively connected to each of the phases of the AC line supply via an isolation transformer (121),

a first bidirectional DC-DC conversion stage (13), configured for implementing the recharging of an electrical storage battery (59);

a second bidirectional DC-DC conversion stage (14), configured for implementing the recharging of the user battery (58) to be recharged;

the first DC-DC conversion stage (13) being furthermore configured in such a manner as to be able to inject current taken from the storage battery (59) onto the power DC bus.

8. The device as claimed in claim 1, characterized in that the control circuit (22) carries out the regulation (55) of the charging or discharge current of the storage battery (59), the regulation (54) of the charging current of the user battery (58) and also the regulation (56, 57) of the power consumed from the AC line supply (61), this regulation being carried out by measuring the charge currents of the storage battery (59) and of the user battery (58) and also the current consumed from the AC line supply (61) and by applying to each of the AC-DC or DC-DC conversion modules (122, 13, 14) a chopping signal whose duty cycle varies as a function of the current measurement carried out for the module in question.

9. The device as claimed in claim 8 characterized in that the chopping signal applied to each of the modules (122a, 122b, 122c, 13, 14) depends on setpoint values relating to the voltage and to the charging current of the user battery (58), to the value (52) of the voltage of the power DC bus (23, 24) and to the maximum power available (51) from the line supply.

10. The device as claimed in claim 1, characterized in that the accommodation structure (31) comprises a support (27) onto which the housings enclosing the various switching modules forming the device are mounted, the support (27) forming a heat dissipation element, as well as a conductor device forming the power DC bus, which connects in parallel the various switching modules mounted onto the accommodation structure (31), each of the links (23, 24) of the power DC bus being connected to each of the switching modules via a suitable connection means.

11. The device as claimed in claim 10, characterized in that, the switching modules being configured in such a manner that when they are mounted onto the accommodation structure (31) their connection points with the two links (23, 24) forming the power DC bus are aligned in two parallel rows, the power DC bus is composed of two conducting plates (23, 24) separated by an insulator (25), each plate having connection areas arranged so as to be disposed facing connection points in such a manner as to be able to be connected to the latter by suitable fixing means.

12. The device as claimed in claim 11, characterized in that the power DC bus consists of two layers of conducting material (23, 24) placed on the opposite faces of a plane layer of electrically insulating material (25) forming a sandwich structure.

13. The device as claimed in claim 2, characterized in that it comprises a switching module (13) configured for implementing the connection of an electrical energy storage battery (59), of given voltage, to the power DC bus, in such a manner that the storage battery (59) can be charged via the power DC bus or else discharged into the latter.

14. The device as claimed in claim 3, characterized in that it comprises a switching module (13) configured for implementing the connection of an electrical energy storage battery (59), of given voltage, to the power DC bus, in such a manner that the storage battery (59) can be charged via the power DC bus or else discharged into the latter.