Distributed Single-Stage On-Board Charger Circuit Topology
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Solution Overview
Problem
Existing electric vehicle charging systems require complex circuits and high-power components to achieve both step-up and step-down charging functions, leading to increased cost and volume, and lack efficiency in power conversion.
Innovation Solution
A distributed single-stage on-board charging device utilizing two transformers in parallel, with capacitors and transistors, performs power factor correction and achieves step-up or step-down conversions for both positive and negative half-waves of AC power, eliminating the need for a DC to DC converter and simplifying the circuit topology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an existing charging system uses both step-up and step-down charging functions, then the charging versatility is improved, but the circuit complexity increases
Solution Approach 1:
The patent applies a single-stage bidirectional DC-DC converter that can operate in both step-up and step-down charging modes. The converter uses a unified circuit topology with switches S1 and S2 that can be controlled to achieve different conversion ratios, eliminating the need for separate circuits for step-up and step-down functions. This multi-functional approach resolves the contradiction by providing charging versatility without increasing circuit complexity.
Solution Approach 2:
The patent merges the step-up and step-down charging functions into a single integrated circuit stage. By combining the voltage conversion functions that were previously required to be separate into one unified converter, the patent achieves both charging modes without the need for additional high-power storage inductors or separate circuit topologies, thus reducing overall system complexity.
2Adaptability or versatility
If an existing charging system uses high-power storage inductor to achieve both step-up and step-down charging, then the charging versatility is improved, but the device volume and cost increase
Solution Approach 1:
The patent merges the step-up and step-down charging functions into a single integrated circuit stage. By combining the voltage conversion functions that were previously required to be separate into one unified converter, the patent achieves both charging modes without the need for additional high-power storage inductors or separate circuit topologies, thus reducing overall system complexity.
Solution Approach 2:
The patent applies a single-stage bidirectional DC-DC converter that can operate in both step-up and step-down charging modes. The converter uses a unified circuit topology with switches S1 and S2 that can be controlled to achieve different conversion ratios, eliminating the need for separate circuits for step-up and step-down functions. This multi-functional approach resolves the contradiction by providing charging versatility without increasing circuit complexity.
3Reliability
If an existing charging system uses separate circuits for charging and driving systems, then the system reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent integrates the charging system and driving system power conversion functions into a unified architecture. The single-stage bidirectional DC-DC converter can serve both charging operations (converting AC to DC for battery charging) and driving operations (providing power to motors), reducing the number of independent circuits while maintaining system reliability through coordinated control of the switching devices.
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 reduces the number of power components, simplifies the circuit, and achieves high efficiency in power conversion, enabling both step-up and step-down charging while meeting automotive safety regulations and improving energy utilization.
Implementation Method 1
performing, by a first transformer, a first step-up or step-down converting for a positive half-wave of the AC power; performing, by a second transformer, a second step-up or step-down converting for a negative half-wave of the AC power
Data Source
AI summary
A distributed single-stage on-board charging device comprises a first transformer having a first primary winding and a first secondary winding; a first capacitor connected to the first primary winding; a first inductor connected to the first capacitor, wherein the first capacitor is located between the first inductor and the first transformer; a first transistor connected to the first capacitor and the first inductor; a first diode connected to the first secondary winding; a second transformer having a second primary winding and a second secondary winding, wherein the first transformer and the second transformer are connected in parallel; a second capacitor connected to the second primary winding; a second inductor connected to the second capacitor, wherein the second capacitor is located between the second inductor and the second transformer; and a second transistor connected to the second capacitor and the second inductor.