Configurable Power Converter for EV Charging
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Solution Overview
Problem
Existing DC fast chargers for Electric Vehicles face challenges in efficiently delivering a wide range of DC output voltages (150V to 1500V) while maintaining high power delivery, leading to high costs and design complexity due to the need for reconfiguring DC-DC converters between series and parallel connections, and compliance with various charging standards like CHAdeMO.
Innovation Solution
A configurable power converter with multiple isolated DC-DC converters that can be selectively configured in series or parallel using configuration selection modules and switches, allowing for flexible voltage and current output adjustments to match different EV requirements without increasing costs or complexity, and ensuring compliance with charging standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If constant high-power requirement is maintained over the wide range of output voltage, then the current rating of the isolated DC-DC converter is high at low voltages, but this increases the costs
Solution Approach 1:
The system divides the power delivery function into multiple isolated DC-DC converters that can be independently controlled and configured. Instead of using a single high-rated converter, the patent segments the power conversion into parallel or series combinations of lower-rated converters, reducing individual component complexity while maintaining overall high power capability.
Solution Approach 2:
The system dynamically reconfigures the connection topology of DC-DC converters between parallel and series configurations based on the required output voltage level. This dynamic reconfiguration allows the same hardware to adapt to different voltage requirements (150V-1500V range) without requiring separate high-voltage and high-current rated converters for each scenario.
2Adaptability or versatility
If two or more low voltage and low current isolated DC-DC converters are connected in parallel at low voltage range and in series at high voltage range, then the voltage and current requirements are met, but mechanical contactors are slower in operation and require large space
Solution Approach 1:
The patent replaces mechanical contactors with solid-state semiconductor switches for reconfiguring the DC-DC converter connections. This substitution eliminates the need for large mechanical contactors, reducing space requirements and improving switching speed. The semiconductor switches are controlled by a controller that receives voltage level signals to determine whether to connect converters in parallel or series configuration.
3Adaptability or versatility
If mechanical contactors are used to change connection between series and parallel, then the reconfiguration is possible, but the mechanical contactors are slower in operation
Solution Approach 1:
The patent replaces mechanical contactors with solid-state semiconductor switches for reconfiguring the DC-DC converter connections. This substitution eliminates the need for large mechanical contactors, reducing space requirements and improving switching speed. The semiconductor switches are controlled by a controller that receives voltage level signals to determine whether to connect converters in parallel or series configuration.
4Adaptability or versatility
If the output voltage is adjusted to match different EV battery voltage ratings, then various EV types can be charged, but the DC output voltage requires a wide range from 150V to 1500V
Solution Approach 1:
The patent creates a universal charging system that can serve multiple EV types with different voltage requirements (150V to 1500V) using the same hardware infrastructure. By incorporating multiple isolated DC-DC converters that can be reconfigured in parallel or series connections, the system achieves multi-functionality, adapting to various battery voltage ratings without requiring separate charging equipment for each EV type.
Data Source
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AI summary
A configurable power converter (201), a charging device (200) and a method (500) for transferring power to an EV (106) from a power grid are provided. The configurable power converter (201) includes two or more isolated DC-DC converters (102C1-102Cn) and one or more configuration selection modules (2021-202n), each electrically coupling two of the isolated DC-DC converters (102C1-102Cn) in a series configuration or a parallel configuration, and including a configuration selection switch (S1)and diodes (D1-D3) electrically coupled to the isolated DC-DC converters (102C1-102Cn).