Charging Plug Integrating AC/DC Converter to Reduce EV Weight
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Solution Overview
Problem
Existing charging systems for electric vehicles require a separate vehicle-end charging device with an AC/DC converter and control unit, which increases weight and complexity, and results in line losses during charging.
Innovation Solution
Integration of the vehicle-end AC/DC converter and monitoring/control device directly into the charging plug, eliminating the need for a separate charging device and minimizing line losses by delivering direct current for battery charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate vehicle-end charging device with AC/DC converter and control unit is used, then the charging function is achieved, but the vehicle weight increases and system complexity increases
Solution Approach 1:
The patent extracts the AC/DC converter and control unit from the vehicle-end charging device and relocates them to the charging plug. This extraction removes the weight burden from the vehicle while maintaining the charging function, as the converted DC power is delivered directly through the charging cable to the vehicle battery.
Solution Approach 2:
The charging plug serves as an intermediary device that performs the AC/DC conversion function. Instead of the vehicle bearing the converter, the plug acts as a mobile conversion station that delivers ready-to-charge DC power through the charging cable, reducing vehicle weight while ensuring reliable charging.
2Reliability
If the monitoring and control device is arranged as a box in the charging cable, then the charging control function is achieved, but the charging cable handling becomes difficult
Solution Approach 1:
The patent merges the monitoring and control device with the charging plug by integrating it into the plug housing. This combination eliminates the need for a separate box in the charging cable, making the charging cable lighter and easier to handle while maintaining all necessary charging control functions through the integrated device.
3Reliability
If the AC/DC converter is located at the vehicle end, then the charging function is achieved, but line losses occur during power transmission
Solution Approach 1:
The patent applies preliminary action by performing the AC/DC conversion before the power reaches the vehicle through the charging cable. The charging plug converts AC to DC in advance, and the converted DC power is transmitted through the cable to the vehicle battery, eliminating line losses that would occur with AC power transmission.
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 integration reduces the vehicle's weight, simplifies handling of the charging cable, and ensures efficient energy transfer to the vehicle's traction battery without additional line losses, enhancing overall charging efficiency.
Implementation Method 1
a rectifier (12), also called an AC/DC converter, which converts alternating current from a power supply (18) into direct current
Data Source
AI summary
A charging plug for an electrically driven vehicle has a feed line for electrically connecting the charging plug to a charging infrastructure. The charging plug includes power contacts, a signal contact, a rectifier, and a control and protection device. The power contacts and signal contact electrically connect the charging plug to the vehicle. The rectifier is connected to the feed line and to the power contacts for converting an alternating current obtained by the feed line into a direct current that is delivered by the power contacts to the vehicle in a charging process. The control and protection device is connected to the feed line, to the power contacts and to the signal contact for matching the charging process to the vehicle by means of the signal contact.