Vehicle Charger Burst-Mode Control for Low-Power Efficiency
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Solution Overview
Problem
Chargers in electrified vehicles experience reduced power conversion efficiency when input electric power is less than the rated power due to external factors such as charging cable and power source specifications, leading to inefficiencies.
Innovation Solution
A control device in the charger intermittently operates the power converter based on the maximum input electric power and rated power, using voltage and current sensors to optimize efficiency by implementing burst mode operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the charger is designed to maximize power conversion efficiency at rated power, then efficiency is improved at maximum input power, but efficiency deteriorates when input power is below rated power
Solution Approach 1:
The patent applies dynamics by making the power converter's operation mode adjustable based on input power conditions. The control device dynamically switches between continuous operation (when input power ≥ rated power) and intermittent operation (when input power < rated power), allowing the system to adapt its behavior to different operating conditions and maintain high efficiency across the full power range
Solution Approach 2:
The patent implements periodic action through intermittent operation of the power converter. When input power is below rated power, the converter operates in bursts with periodic pause periods, rather than continuously. This periodic operation allows the converter to maintain high efficiency by operating at optimal power levels during active periods while pausing during low-power intervals
2Productivity
If the power converter operates continuously, then productivity is improved, but power conversion efficiency deteriorates at low input power levels
Solution Approach 1:
The control device implements periodic action by switching the power converter between active operation and pause periods when input power is below rated power. During active periods, the converter processes power at efficient levels; during pause periods, it rests to avoid inefficient low-power operation. This periodic cycle maintains both productivity and efficiency
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the operation parameters of the power converter based on input power level. When input power drops below rated power, the system changes from continuous operation mode to intermittent operation mode, altering the operational parameters to maintain efficiency while continuing to charge
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
Enhances power conversion efficiency by maintaining efficiency above a predetermined reference value even when input power is below rated power.
Implementation Method 1
a power converter that converts input electric power supplied from an external charging power source into charging electric power supplied to a battery installed in the electrified vehicle
Data Source
AI summary
A charger mounted on an electrified vehicle includes a power converter that converts input electric power supplied from an external charging power source into charging power supplied to a battery mounted on electrified vehicle, and a control device that controls an operation of the power converter, wherein the control device decides a maximum value of the input electric power supplied from the charging power source to the power converter, and intermittently operates the power converter based on the decided maximum value of the input electric power and the rated power of the power converter.