Charging Station Medium-Voltage Transformer Rectifier Modules
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Solution Overview
Problem
Current charging systems for plug-in motor vehicles face limitations in scalability and cost due to system-inherent power restrictions and high procurement costs, particularly when requiring higher charging powers and increased numbers of charging posts, with existing solutions often relying on low-voltage networks with current limits and lacking flexible power distribution.
Innovation Solution
A charging station design that includes a high-power DC/DC converter with galvanic decoupling of vehicles, a buffer store for peak load management, power factor correction filters for improved EMC, and a multi-pole DC busbar for ease of maintenance, allowing flexible expansion and reduced costs by utilizing a medium-voltage network and integrating insulation monitoring for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher charging powers and increased numbers of charging posts are required, then charging capacity and service capability are improved, but system complexity and procurement costs increase
Solution Approach 1:
The charging station is divided into multiple independent charging posts, each with its own AC/DC converter. This modular segmentation allows the system to be expanded by adding individual posts rather than redesigning the entire system, thereby increasing charging capacity while managing system complexity through standardized, replaceable units.
Solution Approach 2:
The charging station is designed with universal components that can serve multiple functions. The AC/DC converters and control systems are configured to work across different charging posts, allowing the same hardware architecture to support varying power levels and vehicle types, thus improving productivity without proportionally increasing complexity.
2Power
If higher charging powers are required, then charging speed and user satisfaction are improved, but system-inherent power restrictions and network limitations worsen
Solution Approach 1:
The system transitions from low-voltage AC networks (400V with 120A current limit) to medium-voltage networks (20kV), fundamentally changing the electrical parameters. This parameter change enables higher power transmission (P=UI) without being constrained by the current limits of low-voltage networks, thereby achieving higher charging powers while maintaining supply reliability.
Solution Approach 2:
A power transformer is introduced as an intermediary device to couple the medium-voltage network to the charging posts. This transformer mediates between the high-voltage supply and the lower-voltage charging requirements, enabling power transfer at medium voltage while ensuring compatibility with vehicle charging systems, thus resolving the conflict between high power delivery and network limitations.
3Productivity
If multiple vehicles are charged simultaneously, then service efficiency is improved, but galvanic coupling between vehicles creates safety and control complexity
Solution Approach 1:
The system extracts the galvanic coupling between vehicles by implementing galvanic decoupling at each charging post. This isolation allows multiple vehicles to be charged simultaneously without their electrical systems being interconnected, thereby improving service efficiency while reducing control and safety complexity associated with multi-vehicle electrical coupling.
4Device complexity
If low-voltage networks with current limits are used, then system simplicity is maintained, but power distribution capability and charging speed are restricted
Solution Approach 1:
The system changes the voltage parameter from low-voltage (400V) to medium-voltage (20kV) operation. Since power P=UI, increasing the voltage parameter allows significantly higher power distribution capability while maintaining reasonable current levels. This parameter change resolves the contradiction by enabling high power capability while the modular design keeps overall system complexity manageable.
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 solution enables flexible and cost-effective charging with sufficient power distribution, avoiding system-inherent power restrictions, reducing procurement costs, and enhancing safety and maintenance through galvanic decoupling and advanced power management, while ensuring compliance with legal power factors and electromagnetic compatibility.
Implementation Method 1
a power transformer (14) having a primary side and a secondary side with at least one terminal lead (18)
Implementation Method 2
at least four rectifier modules (16) which are connected to one another and to the secondary side of the power transformer (14)
Implementation Method 3
a buffer store with feedback capability, and one of the terminal leads (18) of the power transformer (14) is connected to the buffer store
Data Source
AI summary
A charging station (10) for charging a plug-in motor vehicle (24) at a charging post (12) has a power transformer (14) and rectifier modules (16). The power transformer (14) has terminal leads (18) that are DC-isolated on the secondary side. The terminal leads (18) are connected at least partially to the rectifier modules (16). The power transformer (14) and the rectifier modules (16) are configured so that the rectifier modules (16) emit a low DC voltage when the power transformer (14) is fed with a medium voltage.