Dual DC Charging Port Circuit With Hinged Cover for High-Voltage EVs
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Solution Overview
Problem
Existing charging ports for electric vehicles, particularly agricultural work vehicles like tractors, lack safety measures and efficient charging capabilities, limiting their ability to handle high voltage battery systems and fast charging protocols.
Innovation Solution
The development of charging ports for electric vehicles that incorporate safety features such as a cover with a hinge, allowing for easy access while protecting the charging ports, and the ability to charge via both DC Fast Charging and AC grid power, ensuring compatibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is added to protect the charging ports, then safety and protection are improved, but device complexity increases
Solution Approach 1:
The cover is divided into a fixed portion and a movable portion that can be independently positioned. The movable portion can be opened to expose the charging ports when needed and closed to protect them when not in use, providing safety without requiring a completely enclosed complex structure.
Solution Approach 2:
The cover transitions from a static enclosed structure to a dynamic structure with movable portions that can be opened and closed. This allows the charging ports to be protected when not in use while being accessible when charging is needed, resolving the contradiction between protection and accessibility.
2Power
If multiple DC charge ports are provided for fast charging, then charging speed and power are improved, but device complexity increases
Solution Approach 1:
The charging system is segmented into multiple independent DC charge ports (first DC charge port and second DC charge port) that can receive separate cable connections. This allows parallel charging channels to increase total power input without requiring a single complex high-power connector.
Solution Approach 2:
Multiple DC charge ports provide universal charging capability by accepting different cable types and configurations. The system can handle both single-cable and dual-cable charging scenarios, increasing power flexibility without requiring specialized proprietary connectors.
3Ease of operation
If the hinge connection portion is positioned between the two DC charge ports, then ease of operation is improved, but the risk of magnetic interference increases
Solution Approach 1:
The hinge connection portion acts as an intermediary element positioned between the two DC charge ports. By placing the hinge in this intermediate position rather than at the edge, it serves as a spatial separator that reduces magnetic interference between the two charging cables while still allowing easy cover operation.
4Object-affected harmful factors
If the distance between cable centers is made greater than the hinge width, then magnetic interference is reduced, but the area occupied by the charging port assembly increases
Solution Approach 1:
The cover's movable portion dynamically adjusts the effective spacing between charging ports. When the cover is closed, it maintains a compact form factor. When opened for charging, the movable portion allows adequate cable separation distance to reduce magnetic interference without permanently increasing the overall assembly area.
Data Source
AI summary
An electric vehicle (EV) includes a battery pack, a first housing to house at least one first battery module included in the battery pack, a power distribution unit (PDU) to distribute power to the battery pack, a PDU housing that houses the PDU, and at least one DC charge port to connect to a DC voltage source to charge the battery pack. The at least one DC charge port is attached to the PDU housing, and the PDU housing is attached to the first housing.