Dual DC/DC Controllers for Charging Station Battery Integration

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Solution Overview

Problem

Existing electricity charging stations face inefficiencies due to separate housing for energy storage batteries and charging columns, leading to suboptimal voltage range utilization and increased installation complexity, especially with outdated IGBT technologies requiring more space.

Innovation Solution

Integrating the energy storage battery into the same housing as the power electronics system, utilizing two DC/DC controllers downstream of galvanic isolation, with one controller managing the battery and the other for vehicle charging, and employing fast converter topologies with SiC MOS modules to enhance efficiency and compactness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the energy storage battery is housed separately from the charging column, then installation flexibility is improved, but installation complexity and space requirements increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the energy storage battery housing with the charging column housing, integrating two previously separate components into a single unified structure. This eliminates the need for separate installation locations and reduces overall installation complexity while maintaining flexibility through modular internal design.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If outdated IGBT technology is used in the power electronics system, then production costs are reduced, but space requirements and installation complexity increase

Engineering Contradiction:

Improveproduction costVSAvoidspace requirement

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent transitions from IGBT technology to SiC MOS technology, changing the technological parameter of the power electronics system. This advancement enables higher switching frequencies and more compact converter topologies, reducing the physical space required while improving overall system efficiency and performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

By adopting SiC MOS modules, the patent enables the use of three-phase bridgeless PFC converters and other advanced topologies that operate in higher dimensional electrical space, achieving the same power conversion function in a more compact physical footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If a single DC/DC controller is used for both battery and vehicle charging, then device complexity is reduced, but voltage range utilization and battery capacity usage become suboptimal

Engineering Contradiction:

Improvecontroller quantityVSAvoidbattery capacity usage

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent segments the DC/DC control function into two independent controllers: one dedicated to battery management and another dedicated to vehicle charging. This segmentation allows each controller to be optimized for its specific function, enabling full utilization of the battery voltage range and maximum battery capacity for charging operations.

Inventive Principle:

Principle #1Segmentation

4Device complexity

If the energy storage battery is integrated into the same housing as the power electronics system, then installation complexity is reduced, but thermal management challenges increase

Engineering Contradiction:

Improveinstallation complexityVSAvoidthermal management

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The patent combines the battery housing with the power electronics housing, integrating thermal management resources. The power electronics system's cooling infrastructure is shared with the battery, enabling efficient heat dissipation for both components through a unified thermal management approach.

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration optimizes battery capacity usage, reduces installation complexity, and minimizes space requirements, improving charging station efficiency and reducing production costs while maintaining compactness for road traffic visibility.

Implementation Method 1

employing fast converter topologies with SiC MOS modules to enhance efficiency and compactness

Methodology Applied

Scientific EffectSilicon carbide (SiC) semiconductor switching:

Data Source

PatentUS10974612B2Use of two DC/DC controllers in the power electronics system of a charging station or electricity charging station

Publication Date: 2021.04.13 DR ING H C F PORSCHE AG

AI summary

A power electronics system of an electricity charging station having the following features: a first DC voltage converter, a first DC chopper connected to the first DC voltage converter for connection of a battery to the charging station and a second DC chopper connected to the first DC voltage converter for connection of an electric automobile to the charging station and a corresponding electricity charging station,