Dual-Source EV Charging Module for 100% Duty Cycle Output
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Solution Overview
Problem
Conventional residential charging stations for electrified vehicles are limited by alternating current (AC) electrical grid limitations, resulting in a maximum 50% duty cycle for direct current (DC) charging, which restricts charging speed and can be costly to upgrade, particularly for vehicles that require faster charging and power off-loading capabilities.
Innovation Solution
A multi-input, single-output (MISO) DC-DC charging module with a controller that synchronizes and overlays DC inputs from a residential charging station and a wireless inductive charging pad to produce a single DC output at a higher 100% duty cycle, enabling faster charging of the high voltage battery system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the charging station power rating is doubled to achieve faster charging, then the charging speed increases, but the consumer cost and vehicle cost significantly increase
Solution Approach 1:
The patent combines two separate DC power sources (each capable of 50% duty cycle operation) into a single charging system that delivers equivalent power at 100% duty cycle. The controller synchronizes and merges the two inputs, allowing the battery to receive continuous full-power charging without requiring a single expensive high-power charging station, thus achieving faster charging while avoiding increased costs
Solution Approach 2:
The patent divides the charging function into two separate DC power sources operating in parallel, each handling 50% of the total charging capacity. This segmentation allows the system to achieve full-power charging (100% duty cycle) by combining two lower-cost, lower-power sources rather than requiring one expensive high-power source, resolving the contradiction between charging speed and cost
2Power
If a single high-power DC charging station is used to achieve faster charging, then the charging duty cycle increases, but the charging module cost and size/weight increase
Solution Approach 1:
The patent merges two separate DC power inputs through a controller that synchronizes their operation. The combined output delivers equivalent power to a single high-power source but uses two lower-power sources instead, reducing the complexity, cost, and size of the charging module while maintaining high charging power capability
Solution Approach 2:
The charging system is segmented into two independent DC power sources, each operating at 50% duty cycle. This segmentation avoids the need for a single complex high-power charging module, distributing the power delivery function across two simpler, smaller, and less expensive components that work in parallel
3Device complexity
If conventional single-input DC charging is used, then the system is simpler, but the charging rate is limited to 50% duty cycle
Solution Approach 1:
The charging system uses two separate DC power sources operating in parallel, each capable of 50% duty cycle operation. By segmenting the charging function across two inputs, the system achieves a combined 100% duty cycle output, effectively doubling the charging rate while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The controller synchronizes the two DC power inputs in advance, aligning their duty cycles to ensure continuous power delivery. This preliminary synchronization action enables the system to maintain 100% duty cycle operation without complex real-time power electronics, achieving high productivity with relatively simple control logic
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 solution allows for twice the current to be delivered to the high voltage battery system, significantly speeding up the charging process while maintaining cost-effectiveness and reducing the need for expensive upgrades, enhancing the flexibility and ownership experience for drivers.
Implementation Method 1
the controller merges the two DC inputs by synchronizing and overlaying the two DC inputs into the single DC output
Implementation Method 2
the second DC power source is a wireless inductive charging pad
Data Source
AI summary
Charging control techniques for a high voltage battery system of an electrified vehicle utilizes a multi input, single output (MISO) direct current to direct current (DC-DC) charging module configured to connect to two distinct DC power sources and to the high voltage battery system and a controller configured to control the MISO DC-DC charging module to receive, from first and second DC power sources, first and second DC inputs at first and second duty cycles, respectively, merge the two DC inputs into a single DC output at a higher third duty cycle, and output the single DC output to charge the high voltage battery system, wherein the single DC output at the higher third duty cycle provides for faster charging of the high voltage battery system compared to one of the two DC inputs at the respective lower first or second duty cycles.