EV Charging Inverter Integration for Compact Dual-Mode Charging
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Solution Overview
Problem
The increasing demand for electrified vehicles has led to a need for reducing the number of elements and area occupied by on-board chargers in battery charging systems, particularly in both rapid and slow charging systems, to enhance space utilization and efficiency.
Innovation Solution
The proposal involves substituting DC/DC converters with an inverter for motor driving in battery charging systems, utilizing an external voltage conversion device with a power factor correction circuit that includes switching circuits and a transformer, allowing for both rapid and slow charging capabilities through a single charging port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the charging capacity of the on-board charger is increased to increase the range of the electrified vehicle, then the charging performance is improved, but the number of elements used and the area occupied by the on-board charger increases
Solution Approach 1:
The inverter is designed to perform multiple functions: it serves as both the motor driving inverter and the DC/DC converter for battery charging. By integrating these functions into a single device, the patent eliminates the need for separate DC/DC converter components, thereby reducing the overall area occupied while maintaining high charging capacity
Solution Approach 2:
The patent merges the DC/DC converter function with the inverter by configuring the inverter to operate in both motor driving mode and battery charging mode. This consolidation of functions into a single device reduces the number of elements and the total area required for the on-board charger system
2Adaptability or versatility
If separate DC/DC converters are used for rapid charging and slow charging, then both charging modes can be supported, but the number of elements and area occupied increases
Solution Approach 1:
The inverter is designed to universally support both rapid charging and slow charging modes through its dual operational capability. The same inverter hardware performs DC/DC conversion for both charging types, eliminating the need for separate DC/DC converters and reducing device complexity
Solution Approach 2:
The inverter dynamically switches between different operational modes (motor driving and battery charging) based on charging requirements. This dynamic adaptability allows a single device to replace multiple static components, reducing the number of elements while maintaining versatility
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 number of elements and area required for the battery charging system, increases the utility of inner vehicle space, and enables the use of both rapid and slow charging ports by supporting an external power conversion device with a power factor correction circuit.
Implementation Method 1
a transformer connected between the first switching circuit and the second switching circuit
Data Source
AI summary
An embodiment is battery charging system including an external voltage conversion device including an input unit configured to receive a system AC voltage, an output unit configured to output a charging DC voltage, and a power factor correction circuit including a first switching circuit connected to the input unit, a second switching circuit connected to the output unit, and a transformer connected between the first switching circuit and the second switching circuit, and an electrified vehicle including a charging port configured to receive the charging DC voltage, a battery, a motor having a plurality of windings, an inverter connected to each of one-side ends of the plurality of windings, and a relay connected between the charging port and a neutral terminal for the plurality of windings, the electrified vehicle controlling the relay upon recharging of the battery.