Configurable DC-DC Converter Rectifier Switching for Wide EV Voltage Range
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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, leading to restricted operation and efficiency issues, especially with the move from 400 V to 800 V systems.
Innovation Solution
A configurable DC-DC converter system with secondary configuration switches that can operate in single, parallel, and series rectifier configurations, controlled by a controller to adapt to varying battery voltages, combined with a Power Factor Correction (PFC) converter stage, allowing operation with a wide range of input voltages and output voltages, and utilizing resonant tank elements for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-stage layout with AC-DC PFC converter and isolated DC-DC converter is used, then high power density is achieved, but the charger cannot operate at high efficiency for different power requirements and voltage ranges
Solution Approach 1:
The patent implements dynamic reconfiguration of the bridge rectifier circuit using secondary configuration switches that can change the circuit topology between single, parallel, and series configurations. This dynamic adjustment allows the charger to adapt to different voltage ranges (170V-850V) and power requirements, resolving the contradiction between fixed high power density design and variable operational adaptability
Solution Approach 2:
The bridge rectifier circuit is designed with multi-functionality to operate in three different configurations (single, parallel, series) through the use of configuration switches. This universal design enables the same hardware to handle both single-phase and three-phase inputs across wide voltage ranges, eliminating the need for separate circuits for different power requirements while maintaining high power density
2Reliability
If the charger is configured for specific applications, then it meets specific power requirements, but it cannot operate efficiently across different voltage ranges from 170V to 850V
Solution Approach 1:
The patent uses dynamic switching of configuration switches to reconfigure the bridge rectifier circuit topology based on the detected voltage range and power requirements. This allows the charger to maintain reliable, application-specific performance while adapting to voltage ranges from 170V to 850V, resolving the contradiction between specialized optimization and broad compatibility
3Stress or pressure
If single or parallel bridge rectifier configuration is used, then the system operates at lower voltage, but it cannot efficiently handle high voltage up to 850V
Solution Approach 1:
The patent dynamically reconfigures the bridge rectifier from single/parallel to series configuration when high voltage (up to 850V) is detected. This dynamic topology change allows the system to maintain low component stress at low voltages while efficiently handling high voltages through series connection, resolving the contradiction between low-voltage safety and high-voltage capability
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 wider operational voltage ranges, enabling efficient charging and power supply capabilities across different voltage levels, reducing stress on components and allowing for bidirectional operation, including vehicle-to-grid functionality.
Implementation Method 1
utilizing resonant tank elements for enhanced efficiency
Data Source
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AI summary
A system for a direct current (DC) to DC converter (130), the system comprising one or more transformers (240), a bridge driver (210) connected to a primary side of the one or more transformers (240), a first bridge rectifier (220) connected to a secondary side of the one or more transformers (240), a second bridge rectifier (230) connected to a 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.