DC/DC Voltage Regulation Module for Seamless EV Charging Transitions
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Solution Overview
Problem
Existing charging modules for electric vehicles struggle to regulate output voltage across a wide range, leading to potential power-off during transitions between low-voltage and high-voltage states, which disrupts charging and reduces battery life.
Innovation Solution
A voltage regulation module utilizing DC/DC converters and controllable switches, with semiconductor devices, allows seamless switching between series and parallel circuits to adjust output voltage without power-off, using a processor to control the sequence of switch and device states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the charging module uses a single DC/DC converter with fixed circuit configuration, then the device structure is simple, but the output voltage cannot be regulated in a wide range
Solution Approach 1:
The charging module is divided into a first DC/DC converter and a second DC/DC converter, each handling different voltage ranges. The first converter handles low-voltage output (300-500V) while the second handles high-voltage output (550-950V), allowing the system to adapt to different battery voltage requirements without requiring a completely different circuit configuration for each range.
Solution Approach 2:
The circuit configuration dynamically switches between series and parallel connections based on the required output voltage. When high voltage is needed, the DC/DC converters connect in series; when lower voltage is needed, they connect in parallel. This dynamic reconfiguration enables wide voltage regulation range while using standardized converter modules.
2Adaptability or versatility
If the charging module switches between low-voltage and high-voltage output states using traditional power-off methods, then the voltage regulation range is achieved, but power-off occurs during switching which disrupts charging
Solution Approach 1:
The semiconductor devices (IGBTs or MOSFETs) enable continuous current flow during voltage state transitions. By controlling the switching sequence of these devices, the system maintains uninterrupted power delivery to the battery while transitioning between low-voltage and high-voltage output states, eliminating charging disruptions.
Solution Approach 2:
Before switching between voltage states, the control processor pre-configures the switching states of the semiconductor devices to ensure smooth transition. The system prepares the circuit configuration in advance, adjusting the conduction states of the semiconductor devices progressively rather than abruptly, which prevents power-off during switching.
3Adaptability or versatility
If expensive relays are used to switch between series and parallel circuits, then the circuit switching capability is achieved, but the device cost increases
Solution Approach 1:
The patent replaces mechanical relay switches with semiconductor devices (IGBTs or MOSFETs) controlled by a processor. These semiconductor switches are integrated into the DC/DC converter circuits and can be controlled electronically without mechanical contact, eliminating the need for expensive high-voltage relays while achieving the same circuit switching functionality.
Solution Approach 2:
The semiconductor devices serve multiple functions: they act as switches for circuit configuration, provide voltage regulation, and enable protective functions. This multi-functionality eliminates the need for separate relay components, reducing overall device cost while maintaining circuit switching 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
Enables wide-range voltage regulation with seamless transitions, improving charging experience and extending battery life by preventing power disruptions and reducing the need for expensive relays.
Implementation Method 1
The charging module is a high-frequency switch-mode power supply, and is used to convert alternating current power into direct current power
Implementation Method 2
An output negative terminal of the first DC/DC converter module is connected to an output positive terminal of the second DC/DC converter module by using the first controllable switch module
Data Source
AI summary
A voltage regulation module, a charging module, and a charging pile may be used to charge an electric vehicle, to regulate an output voltage in a wide range, and to implement seamless switching without power-off in a process of switching from a low-voltage output state to a high-voltage output state. The voltage regulation module includes a first DC/DC converter group and a second DC/DC converter group. Both a parallel circuit and a series circuit exist between the first DC/DC converter group and the second DC/DC converter group. In addition, a controllable switch group is disposed in each of the series circuit and the parallel circuit, and a semiconductor device group is connected in parallel with two terminals of each controllable switch group.