Eco-Friendly Vehicle Charger Using MOSFET Switching

Solution Overview

Problem

Eco-friendly vehicle on-board chargers face inefficiencies due to excessive inrush current and power consumption caused by mechanical relays, leading to increased volume and cost, as well as reduced fuel efficiency.

Innovation Solution

A charging device for eco-friendly vehicles utilizing an electronic switching element, such as a MOSFET, controlled by a controller that divides AC voltage into sections to manage the switching element's operation, reducing inrush current through real-time monitoring and optimized control strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a mechanical relay is used to reduce inrush current, then inrush current is reduced, but the volume of the power connector increases and efficiency decreases

Engineering Contradiction:

Improveinrush currentVSAvoidvolume of power connector

Core Design Contradiction:

Object-affected harmful factorsVSVolume of moving object

Solution Approach 1:

The patent replaces the mechanical relay with an electronic switching element (MOSFET) that is controlled by a controller. The controller monitors AC voltage and controls the switching element to reduce inrush current without requiring mechanical moving parts. This substitution eliminates the need for additional heat dissipation components and reduces the overall volume of the power connector while maintaining the inrush current reduction function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the switching element based on real-time AC voltage monitoring. The controller adjusts the switching timing and duration according to the detected voltage level, optimizing the inrush current reduction effect. This dynamic parameter adjustment allows the system to achieve effective inrush current suppression without requiring oversized fixed components.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a mechanical relay is used to reduce inrush current, then inrush current is reduced, but power consumption increases and efficiency decreases

Engineering Contradiction:

Improveinrush currentVSAvoidpower consumption

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical relay with an electronic switching element (MOSFET) that is controlled by a controller. The controller monitors AC voltage and controls the switching element to reduce inrush current without requiring mechanical moving parts. This substitution eliminates the need for additional heat dissipation components and reduces the overall volume of the power connector while maintaining the inrush current reduction function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The switching element and controller work together in a self-regulating manner where the controller monitors the AC voltage conditions and automatically adjusts the switching element operation accordingly. This eliminates the need for separate control circuits and additional power-consuming components that would be required with mechanical relay systems.

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If a mechanical relay is used to reduce inrush current, then inrush current is reduced, but the charger efficiency decreases

Engineering Contradiction:

Improveinrush currentVSAvoidcharger efficiency

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical relay with an electronic switching element (MOSFET) that is controlled by a controller. The controller monitors AC voltage and controls the switching element to reduce inrush current without requiring mechanical moving parts. This substitution eliminates the need for additional heat dissipation components and reduces the overall volume of the power connector while maintaining the inrush current reduction function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the switching element based on real-time AC voltage monitoring. The controller adjusts the switching timing and duration according to the detected voltage level, optimizing the inrush current reduction effect. This dynamic parameter adjustment allows the system to achieve effective inrush current suppression without requiring oversized fixed components.

Inventive Principle:

Principle #35Parameter changes

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 solution reduces the volume of the power connector, minimizes power consumption, and enhances the efficiency of the charger by eliminating the need for mechanical relays and additional heat dissipation components, thereby improving the overall efficiency and packaging density of the charging system.

Implementation Method 1

an electronic switching element which reduces an excessive current instantaneously flowing when an external AC power source outside the vehicle is connected to the charger

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS9937804B2Charging device for eco-friendly vehicle and control method of the same

Publication Date: 2018.04.10 HYUNDAI MOTOR CO LTD

AI summary

A charging device for an eco-friendly vehicle includes a charger having an electronic switching element which reduces an excessive current instantaneously flowing when an external AC power source outside the vehicle is connected to the charger; and a controller configured to control an operation of the electronic switching element.