Configurable DC-DC Converter Topology for 400V-800V Battery Charging
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Solution Overview
Problem
Existing battery chargers for electric vehicles face challenges in achieving high efficiency and power density due to limitations in voltage range compatibility with single-phase and three-phase input supplies, particularly with the transition from 400 V to 800 V systems, where conventional converters struggle to maintain efficiency and power operation across a wide range of voltages.
Innovation Solution
A configurable DC-DC converter system with multiple transformer configurations and resonant tank elements, controlled by a controller that dynamically adjusts bridge driver and rectifier configurations (single, parallel, and series) based on sensed battery voltage, allowing operation across a wide range of input and output voltages, and enabling bidirectional power flow for vehicle-to-grid applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional DC-DC converter is designed for specific voltage ranges, then it can operate efficiently within that range, but it cannot maintain high efficiency and power operation across a wide range of voltages from 400V to 800V systems
Solution Approach 1:
The patent implements dynamic reconfiguration of the bridge driver and rectifier configurations (single, parallel, and series) based on sensed battery voltage levels. The controller dynamically switches between different operational modes to maintain optimal efficiency across the wide voltage range from 400V to 800V DC input supplies, resolving the contradiction between adaptability and energy loss.
Solution Approach 2:
The system changes its operational parameters by switching between different bridge driver configurations (single, parallel, series) and rectifier configurations based on the input voltage level. This parameter change allows the converter to maintain high efficiency across varying voltage conditions, addressing both the adaptability requirement and the efficiency constraint.
2Productivity
If battery chargers are configured for specific applications with fixed configurations, then they can be simple in design, but they cannot operate at high efficiency for different power requirements
Solution Approach 1:
The patent divides the converter into multiple bridge drivers and rectifiers that can be independently configured. The primary side includes multiple bridge drivers that can be connected in single, parallel, or series configurations, while the secondary side includes multiple bridge rectifiers with similar configuration options. This segmentation enables flexible power operation while managing design complexity through modular architecture.
Solution Approach 2:
The converter is designed with multi-functionality to handle different power requirements and voltage levels using the same hardware platform. By incorporating multiple bridge drivers and rectifiers that can be reconfigured through switches, the system provides universal operation across various charging scenarios, from single-phase to three-phase inputs and different battery voltage levels.
3Adaptability or versatility
If the system uses multiple bridge drivers and rectifiers to handle wide voltage ranges, then voltage adaptability improves, but the system complexity increases
Solution Approach 1:
The controller senses the battery voltage level and uses this feedback information to automatically select the appropriate bridge driver and rectifier configuration. This feedback mechanism simplifies the overall system operation by eliminating manual configuration requirements and ensuring the system automatically adapts to the correct operating mode based on real-time voltage conditions.
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 system achieves higher efficiency and power density by dynamically adjusting configurations to match varying voltage conditions, ensuring efficient charging and power supply across a wide range of input voltages and output voltages, thereby overcoming the limitations of conventional chargers.
Implementation Method 1
one or more transformers; a first bridge driver connected to a primary side of the one or more transformers; a first bridge rectifier connected to a secondary side of the one or more transformers
Data Source
Figure 1
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Figure 2
AI summary
A system for a direct current (DC) to DC converter (130), the system comprising one or more transformers (240), a first bridge driver (210) connected to a primary side of the one or more transformers (240), a second bridge driver (260) connected to a primary side of the one or more transformers (240), one or more primary configuration switches (250) operable to configure the first bridge driver (210) and the second bridge driver (260) into each of a single driver configuration, a parallel driver configuration, and a series driver configuration, a first bridge rectifier (220) connected to a secondary side of the one or more transformers (240), a second bridge rectifier (230) connected to the secondary side of the one or more transformers (240), and one or more secondary configuration switches (200) operable to configure the first bridge rectifier (220) and the second bridge rectifier (230) into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration.