Integrated BCCM Booster Circuit for 800V Fast Charging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automotive power systems face challenges in efficiently charging high-voltage batteries due to limitations in power capacity and weight of charging cables, particularly when transitioning from 400V to 800V battery architectures, necessitating innovative solutions to enhance power density and charging efficiency.
Innovation Solution
Integration of a battery current control module (BCCM) with a bidirectional power factor correction circuit, an isolated DC/DC converter, and an active ripple energy storage circuit, along with a booster module that includes a transformer, switching bridge, and switch bank, allowing for optimized current flow and frequency modulation to support both AC and DC charging modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If 400V battery architecture is used with high power charging, then charging power capacity increases, but cable weight increases significantly
Solution Approach 1:
The system changes the voltage parameter from 400V to 800V battery architecture, which allows delivering the same or higher power (350kW+) with lower current, thereby reducing cable weight by approximately 70% while maintaining or improving charging power capacity
2Productivity
If 350kW charging power is delivered at 400V, then charging speed increases, but cable current handling requirement increases to 1000A
Solution Approach 1:
The invention changes the operating voltage parameter to 800V, which reduces the current required for 350kW charging from 1000A to approximately 440A, thereby reducing cable weight and current handling requirements while maintaining high charging speed
3Power
If traditional separate booster module is added to 400V system, then power density increases, but device complexity increases
Solution Approach 1:
The patent merges the booster circuit functionality with the existing battery current control module (BCCM), integrating AC/DC conversion, DC/DC conversion, and battery current control into a single unified module, thereby increasing power density while avoiding the added complexity of a separate booster module
4Loss of time
If fast charging is implemented, then charging time decreases, but power capacity requirements increase
Solution Approach 1:
The system uses 800V battery architecture with integrated booster capability to deliver 350kW or higher power capacity, enabling charging from 20% to 80% state of charge in under 10 minutes by reducing charging time through higher power delivery
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables fast charging of traction batteries from 20% to 80% in under 10 minutes using 800V battery architectures, reducing cable weight and enhancing power density by up to 70% through optimized current management and reduced electrolytic capacitor size.
Implementation Method 1
The isolated DC/DC converter includes a transformer
Implementation Method 2
a switching bridge, and a switch bank connected between the transformer and switching bridge
Data Source
AI summary
An automotive power system has a battery current control module including a bidirectional power factor correction circuit, an isolated DC/DC converter, and an active ripple energy storage circuit connected between the bidirectional power factor correction circuit and isolated DC/DC converter. The system further has a DC charge input connected with the isolated DC/DC converter.