BEV Charger Power Module With Internal SMPS for Reduced Hardware

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Solution Overview

Problem

Existing BEV charging stations with multiple charging cables require extensive hardware, including multiple SMPS units for operational equipment, which can be costly and inefficient.

Innovation Solution

The implementation of a BEV charging station with power modules that include internal SMPS units and an output port for supplying power to operational hardware, reducing the need for separate SMPS units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate SMPS units are used for operational equipment in a BEV charging station with multiple charging cables, then each equipment can be powered independently, but the number of electrical components increases and costs increase

Engineering Contradiction:

Improveindependent power supply for each equipmentVSAvoidnumber of electrical components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple SMPS functions into a single integrated power module that serves both the BEV charging function and operational equipment power supply. The power module includes a controller that can switch between providing full power to a BEV and providing reduced power to operational equipment, eliminating the need for separate SMPS units for each piece of equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power module is designed to perform multiple functions: it can charge a BEV at full power, provide reduced power to operational equipment when no BEV is connected, and transition between these modes. This multi-functional design replaces what would traditionally require separate dedicated power supplies for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate SMPS units are used for operational equipment, then each equipment has dedicated power supply, but the charging station costs more

Engineering Contradiction:

Improvededicated power supply for equipmentVSAvoidcharging station cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the function of multiple separate SMPS units into a single integrated power module, reducing component count and manufacturing cost. The controller within the power module manages power distribution to both BEV charging and operational equipment, eliminating the need for multiple separate power supply units and associated control circuits.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power module is designed as a universal power source that can serve both BEV charging and operational equipment power supply needs. This multi-functional approach reduces the overall bill of materials and manufacturing complexity compared to using dedicated SMPS units for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple separate SMPS units are used for operational equipment, then each equipment can operate independently, but the charging station requires more hardware

Engineering Contradiction:

Improveindependent operation of equipmentVSAvoidnumber of hardware components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple power supply functions into a single integrated power module with a controller that can independently manage power distribution to different loads. The controller can switch between providing full power to BEV charging and reduced power to operational equipment, maintaining independent operation capability while reducing hardware count.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power module incorporates dynamic power management through its controller, which can adjust power output levels based on operational needs. The controller can provide full power during BEV charging and switch to providing reduced power to operational equipment when no BEV is connected, enabling adaptive operation with a single hardware unit.

Inventive Principle:

Principle #15Dynamics

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

This configuration minimizes the number of electrical components, reduces costs, and enhances efficiency by integrating the SMPS within the power modules.

Implementation Method 1

at least one power module having a plurality of switches that rectify alternating current (AC) electrical power received from a power grid into direct current (DC) electrical power supplied to a BEV

Methodology Applied

Scientific EffectRectification:

Implementation Method 2

at least one switched mode power supply (SMPS) internal to the power module

Methodology Applied

Scientific EffectSwitched mode power conversion:

Data Source

PatentUS20250033493A1Multi-output battery electric vehicle charger with switched mode power supply

Publication Date: 2025.01.30 BORGWARNER INC

AI summary

A battery electric vehicle (BEV) charging station includes at least one power module having a plurality of switches that rectify alternating current (AC) electrical power received from a power grid into direct current (DC) electrical power supplied to a BEV; at least one switched mode power supply (SMPS) internal to the power module; and operational equipment electrically connected to the SMPS in the power control module.