Systems and methods for efficient DC fast charging

Patent metadata

Field	Value
Publication number	US-12294234-B2
Application number	US-202117515811-A
Country	US
Kind code	B2
Filing date	Nov 1, 2021
Priority date	Nov 1, 2021
Publication date	May 6, 2025
Grant date	May 6, 2025

Abstract

In an illustrative embodiment, a direct current (DC) fast charger (DCFC) controller unit includes a controller. The controller includes a processor and computer-readable media. The computer-readable media is configured to store computer-executable instructions configured to cause the processor to: receive a maximum charge time duration to charge at least one battery to a desired state of charge responsive to an increased efficiency charge mode being enabled; determine an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration; select a charge cycle for charging the at least one battery to the desired state of charge with a lowest amount of energy used; and cause the at least one battery to be charged with the selected charge cycle.

First claim

What is claimed is:

1. A direct current (DC) fast charger (DCFC) controller unit comprising:
a controller including:
a processor; and
computer-readable media configured to store computer-executable instructions configured to cause the processor to:
receive a maximum charge time duration to charge at least one battery to a desired state of charge responsive to an increased efficiency charge mode being enabled;
determine an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration;
select a charge cycle for charging the at least one battery to the desired state of charge with a lowest amount of energy used; and
cause the at least one battery to be charged with the selected charge cycle.

2. The controller unit of claim 1 , wherein the computer-executable instructions are further configured to cause the processor to determine an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration responsive to efficiency of a charging system, efficiency of the at least one battery, and maximum charge time duration.

3. The controller unit of claim 2 , wherein the efficiency of a charging system is determined responsive to at least one factor chosen from electrical power conversion losses, bias and housekeeping power usage, cooling pump power usage, cooling fan power usage, controller power usage, and display power usage.

4. The controller unit of claim 2 , wherein data regarding efficiency of the at least one battery is provided in a data format chosen from an efficiency curve and effective charge resistance.

5. The controller unit of claim 1 , wherein the computer-executable instructions are further configured to cause the processor to operate at least one charging system cooling component chosen from a cooling pump and a cooling fan at a reduced speed.

6. The controller unit of claim 1 , wherein the charge cycle selected for charging the at least one battery to the desired state of charge with a lowest amount of energy used includes a charge cycle performed using less than a maximum charge power capability of a charging system.

7. The controller unit of claim 1 , wherein the charge cycle selected for charging the at least one battery to the desired state of charge with a lowest amount of energy used includes a charge cycle performed using a maximum charge power capability of a charging system.

8. A direct current (DC) fast charger (DCFC) system comprising:
an electrical power converter configured to convert alternating current (AC) electrical power to DC electrical power, the electrical power converter including a controller including:
a processor; and
computer-readable media configured to store computer-executable instructions configured to cause the processor to:
receive a maximum charge time duration to charge at least one battery to a desired state of charge responsive to an increased efficiency charge mode being enabled;
determine an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration;
select a charge cycle for charging the at least one battery to the desired state of charge with a lowest amount of energy used; and
cause the at least one battery to be charged with the selected charge cycle; and

at least one electrical power dispenser assembly electrically couplable to the electrical power converter and configured to dispense DC electrical power to at least one battery.

9. The DCFC system of claim 8 , wherein the electrical power converter includes:
a plurality of DC power modules configured to convert AC electrical power to DC electrical power; and
a switching matrix configured to electrically connect selected ones of the plurality of DC power modules in parallel to a selected electrical power dispenser assembly.

10. The DCFC system of claim 9 , wherein the computer-executable instructions are further configured to cause the processor to determine a number of the plurality of DC power modules to electrically connect in parallel to the selected electrical power dispenser assembly.

11. The DCFC system of claim 8 , wherein the computer-executable instructions are further configured to cause the processor to determine an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration responsive to efficiency of a charging system, efficiency of the at least one battery, and maximum charge time duration.

12. The DCFC system of claim 11 , wherein the efficiency of a charging system is determined responsive to at least one factor chosen from electrical power conversion losses, bias and housekeeping power usage, cooling pump power usage, cooling fan power usage, controller power usage, and display power usage.

13. The DCFC system of claim 12 , wherein data regarding efficiency of the at least one battery is provided in a data format chosen from an efficiency curve and effective charge resistance.

14. The DCFC system of claim 8 , wherein the computer-executable instructions are further configured to cause the processor to operate at least one charging system cooling component chosen from a cooling pump and a cooling fan at a reduced speed.

15. The DCFC system of claim 8 , wherein the charge cycle selected for charging the at least one battery to the desired state of charge with a lowest amount of energy used includes a charge cycle performed using less than a maximum charge power capability of a charging system.

16. A method comprising:
receiving a maximum charge time duration to charge at least one battery to a desired state of charge responsive to an increased efficiency charge mode being enabled;
determining an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration;
selecting a charge cycle for charging the at least one battery to the desired state of charge with a lowest amount of energy used; and
causing the at least one battery to be charged with the selected charge cycle.

17. The method of claim 16 , wherein determining an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration includes determining an amount of energy used in a plurality of charge cycles for charging the at least one battery to the desired state of charge with charge time durations no longer than the maximum charge time duration responsive to efficiency of a charging system, efficiency of the at least one battery, and maximum charge time duration.

18. The method of claim 16 , wherein selecting a charge cycle for charging the at least one battery to the desired state of charge with a lowest amount of energy used includes selecting a charge cycle performed using less than a maximum charge power capability of a charging system.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Schulz Steven E
• Hiti Silva

Classifications

• H02J7/92 Primary

  with prioritisation of loads or sources · CPC title

• H02J7/50

  acting upon multiple batteries simultaneously or sequentially · CPC title

• H01M10/613

  Cooling or keeping cold · CPC title

• H01M10/441 Primary

  for several batteries or cells simultaneously or sequentially · CPC title

• H02J2207/20

  Charging or discharging characterised by the power electronics converter · CPC title