BEV Charger Switch Topology for Multi-Cable Charging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stationary vehicle battery chargers for battery electric vehicles (BEVs) are costly due to the large number of components, particularly switches, required to handle multiple charging cables, which increases manufacturing expenses.
Innovation Solution
A novel configuration of primary and secondary groups of switches within the charger, coupled with power modules, allows for efficient charging of multiple BEVs using fewer switches than traditional systems, optimizing switch usage and reducing heat and load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional charging systems use separate switches for each power module and charging cable, then charging capability is ensured, but the number of switches increases significantly, leading to higher manufacturing costs and increased system complexity
Solution Approach 1:
The patent combines multiple switching functions into a single intelligent switch device that can dynamically connect any power module to any charging cable. This single switch replaces what would traditionally require multiple separate switches, directly reducing the total number of switches and manufacturing costs while maintaining full charging capability.
Solution Approach 2:
The intelligent switch is designed with multi-functionality to perform multiple switching tasks simultaneously. It can dynamically route power from any power module to any charging cable, serving the function of multiple dedicated switches while being implemented as a single device, thereby reducing system complexity and cost.
2Adaptability or versatility
If more switches are used to handle multiple charging cables, then charging versatility is improved, but switch lifespan is reduced due to increased wear and heat generation
Solution Approach 1:
By merging multiple switching functions into one intelligent switch, the patent reduces the total number of switching operations distributed across multiple devices. This concentration of function in a single robust switch reduces cumulative wear and heat generation, thereby extending switch lifespan while maintaining charging versatility.
Solution Approach 2:
The intelligent switch dynamically adapts its switching configuration based on real-time conditions, optimizing the switching path to minimize wear and heat generation. This dynamic operation allows the system to maintain high versatility while reducing stress on the switching component, thereby extending its operational life.
3Ease of manufacture
If the number of switches is reduced to lower manufacturing costs, then manufacturing expense decreases, but the ability to handle multiple charging cables simultaneously may be compromised
Solution Approach 1:
The intelligent switch is designed with universal functionality to handle multiple charging cables simultaneously through dynamic routing. This single multi-functional switch replaces multiple single-function switches, reducing manufacturing expense while maintaining the system's ability to serve multiple charging cables at the same time.
Solution Approach 2:
The intelligent switch dynamically configures its internal connections to accommodate multiple simultaneous charging operations. This dynamic reconfiguration capability allows the system to maintain high charging capacity with fewer physical switches, thereby reducing manufacturing expense without compromising productivity.
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 reduces the number of switches needed, prolongs switch life, and lowers manufacturing costs while maintaining efficient charging capabilities.
Implementation Method 1
a plurality of power modules configured to receive alternating current (AC) voltage from an electrical grid and rectify the AC voltage into direct current (DC) voltage
Data Source
AI summary
A stationary vehicle charging system for charging batteries carried by battery electric vehicles (BEVs) includes a plurality of power modules configured to receive alternating current (AC) voltage from an electrical grid and rectify the AC voltage into direct current (DC) voltage; a primary group of switches having switches electrically coupled: to the plurality of power modules, with other switches within the primary group of switches via a plurality of primary module busses, and to a charging cable for charging a BEV; and a secondary group of switches having switches electrically coupled to: a plurality of switches within the primary group of switches, with another charging cable for charging a BEV, and configured to electrically couple to one or more secondary busses.