EV Charger DAB Control for Power Pulsation Absorption

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Solution Overview

Problem

Existing chargers for electric vehicles face challenges in reducing the size of capacitors required to absorb power pulsation due to single-phase AC power supply, leading to inefficiencies and bulkiness.

Innovation Solution

A charger design incorporating a Dual-Active-Bridge (DAB) converter with a power pulsation absorbing circuit, utilizing a controller to manage switching of switches in linked manner to achieve a rectangular current waveform, and employing a power factor correction circuit to absorb power pulsation efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a high capacitance capacitor is used to absorb power pulsation in a single-phase AC/DC charger, then the power pulsation can be effectively absorbed, but the size of the capacitor increases significantly

Engineering Contradiction:
Improvepower pulsation absorption capabilityVSAvoidcapacitor size
Core Design Contradiction:
ReliabilityVSVolume of stationary object

Solution Approach 1:

The power pulsation absorption function is segmented from the traditional single large capacitor into multiple smaller capacitors arranged in a specific circuit configuration. The patent uses multiple capacitors (including first, second, third, and fourth capacitors) that work together to absorb power pulsation, distributing the energy storage function across multiple smaller components rather than relying on one large capacitor.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces active switching elements (switches with controlled gating) that dynamically adjust the circuit configuration based on the power pulsation conditions. The switching elements enable the capacitor network to adaptively respond to power pulsation in real-time, optimizing the absorption efficiency while maintaining compact dimensions through dynamic control rather than static oversized components.

Inventive Principle:
Principle #15Dynamics

2Speed

If switches are switched during dead time in a full bridge circuit, then the switching speed is improved, but hard switching occurs which reduces efficiency

Engineering Contradiction:
Improveswitching speedVSAvoidswitching loss
Core Design Contradiction:
SpeedVSLoss of energy

Solution Approach 1:

The patent applies preliminary action by pre-charging or pre-discharging specific capacitors before the main switching event occurs. The switching elements are controlled to prepare the voltage conditions in advance, ensuring that when the actual switching happens, the voltage difference is minimized, thereby avoiding hard switching and reducing energy loss while maintaining fast switching speeds.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent introduces intermediary capacitor elements that act as buffers between the switching elements and the main power circuit. These intermediary capacitors absorb voltage spikes and provide smooth transition during switching events, mediating the energy transfer to prevent hard switching while enabling rapid switching operation.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

The design enables a compact and efficient charger that effectively absorbs power pulsation, reducing the size of capacitors and inductors, thereby enhancing efficiency and compactness.

Implementation Method 1

a rectifier including two input terminals, a cathode terminal and an anode terminal, wherein the two input terminals are configured for connection to an AC power supply

Methodology Applied
Scientific EffectDiode rectification: Diode

Implementation Method 2

a capacitor and a first switch which are connected in series between the first line and the second line with the capacitor being arranged closer to the second line than the first switch

Methodology Applied
Scientific EffectCapacitance: Capacitance

Implementation Method 3

an inductor, a capacitor, a first switch and a second switch; and a controller configured to control switching of switches of the DC/DC converter and switching of the first switch and the second switch, wherein the first diode is connected between the inductor of the power pulsation absorbing circuit and one of the two input terminals of the rectifier

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12573945B2Charger
Publication Date: 2026.03.10 YAZAKI CORP
  • US12573945B2 patent drawing
  • US12573945B2 patent drawing
  • US12573945B2 patent drawing

AI summary

A charger is configured such that in case where control of switching of a DC/DC converter includes a first mode and a second mode, a dead time is provided between the first mode and the second mode when switching from the first mode to the second mode and a first switch of a power pulsation absorbing circuit is controlled to be in an off-state during a time until expiration of a predetermined time after start of the dead time, wherein in the first mode, at least one switch of switches of the DC/DC converter is switched on, at least one switch of the switches of the DC/DC converter is switched off, and the first switch of the power pulsation absorbing circuit is switched off, and wherein in the second mode, the switch of the DC/DC converter which is switched off in the first mode is switched on, and the first switch of the power pulsation absorbing circuit is switched on.