Charging Plug Voltage Converter for Electric Vehicle Power
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Solution Overview
Problem
Current electric vehicle charging technologies face limitations in increasing charging power while adhering to existing standards, leading to lengthy charging times and high manufacturing and maintenance costs due to the need for large cable cross-sections and complex cooling systems, which also result in power losses and increased costs for users.
Innovation Solution
Incorporating a voltage converter within the charging plug that converts a higher supply voltage (up to 1,400 V) to a lower charging voltage, allowing for reduced cable cross-sections and eliminating the need for complex control technology and additional communication lines, thereby simplifying handling and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cable cross-section is increased to handle higher charging currents, then the charging power is improved, but the cable weight and manufacturing costs increase
Solution Approach 1:
The patent changes the voltage parameter from low voltage (400V) to high voltage (1000V or higher) to transmit the same power with lower current, thereby enabling the use of cables with smaller cross-sections and reduced weight while maintaining the required charging power
2Weight of moving object
If the cable cross-section is reduced to decrease weight, then the cable weight is improved, but the electrical resistance increases leading to higher power losses
Solution Approach 1:
By increasing the voltage parameter to 1000V or higher, the patent enables the use of thinner cables with lower resistance while maintaining acceptable power loss levels, as the higher voltage compensates for the increased resistance in smaller cross-section cables
3Temperature
If water cooling is integrated into the charging cable to manage heat, then the thermal management is improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent extracts the cooling function from the charging cable itself, allowing the cable to be simpler and lighter while thermal management is handled separately at the charging station through dedicated cooling infrastructure
Solution Approach 2:
The charging cable is designed for universal use without integrated cooling, while the charging station provides multi-functional support including cooling capabilities that can serve multiple cables and vehicles
4Loss of information
If additional communication lines are added to the charging cable for data transmission, then the communication capability is improved, but the cable weight and manufacturing costs increase
Solution Approach 1:
The patent makes the existing power cable multi-functional by enabling it to carry both power transmission and communication functions through power line communication technology, eliminating the need for separate communication lines
Solution Approach 2:
The patent merges the communication function with the power transmission function by using the same cable infrastructure for both purposes, thereby reducing overall system complexity and cable requirements
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 enables increased charging power with reduced cable size, shorter charging times, and lower manufacturing and maintenance costs, while maintaining compliance with existing standards and safety regulations, and allows for wireless communication and display integration for enhanced user experience.
Implementation Method 1
a voltage converter for converting the supply voltage into a relatively lower charging voltage is arranged in the charging plug
Data Source
Figure 1
Figure 2
Figure 3a~3f
AI summary
The present invention relates to a charging arrangement (1) for an electric vehicle (2) having a traction battery (3), comprising a power supply station (10), connected to a power network and a power supply cable (11) with charging connector (6), wherein, in order to perform a charging process, the charging connector (6) is connected to the electric vehicle (2), characterized in that a voltage converter (9) is arranged in the charging connector (6) to convert the supply voltage Uv into a charging voltage UL which is lower relative to the supply voltage, and a method for operating the charging arrangement (1).