EV Charge Port Switching for 3-Phase AC Charging
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Solution Overview
Problem
Conventional electric vehicle charging systems using the Combined Charging System (CCS) Type 1 connector are limited to 19.2 kW of maximum charging power due to the use of 2-phase AC charging, which does not fully utilize the available power capacity.
Innovation Solution
The system modifies the vehicle charge port to utilize the DC fast charging pins to receive an additional phase of AC current, enabling 3-phase AC charging without altering the physical structure of the charge port or the EVSE connector, thereby increasing the AC charging power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the CCS Type 1 connector is used with 2-phase AC charging, then the charging system is compatible with existing infrastructure, but the maximum charging power is limited to 19.2 kW
Solution Approach 1:
The charge port terminals are designed to serve multiple functions: they can receive 2-phase AC current for standard AC charging, 3-phase AC current for higher power AC charging, or DC current for DC fast charging. The switch arrangement enables the same physical terminals to be configured for different charging modes, making the system universally compatible while enabling higher power delivery.
Solution Approach 2:
The switch arrangement dynamically reconfigures the electrical connections between terminals based on the charging mode detected or selected. When 3-phase AC charging is desired, the switch connects the additional phase through the DC fast charging pins; when DC charging is detected, it establishes direct DC paths. This dynamic switching enables the system to adapt its power delivery capability in real-time.
2Power
If DC fast charging pins are used to receive additional phase AC current, then 3-phase AC charging power is increased, but the physical structure of the charge port must be modified
Solution Approach 1:
The DC fast charging pins, originally designed solely for DC current reception, are repurposed to also receive AC current for 3-phase charging. This multi-functional use of existing pins enables 3-phase AC charging capability without adding new physical connectors or significantly modifying the charge port structure.
Solution Approach 2:
The patent merges the AC charging function and DC fast charging function into a single charge port interface. By using the same physical terminals and switch arrangement for both AC and DC charging modes, the system consolidates multiple charging capabilities into one unified connector, avoiding the need for separate connectors or extensive structural modifications.
3Power
If a switch arrangement is added to enable 3-phase AC charging, then charging power is increased, but the device complexity increases
Solution Approach 1:
The patent combines the switching functionality for both AC and DC charging modes into a single integrated switch arrangement. This switch simultaneously performs multiple functions: routing AC current phases to the onboard charger, routing DC current directly to the battery, and detecting the presence of DC fast charging pins. By merging these functions into one component, the patent reduces overall system complexity compared to using separate switching mechanisms for each charging mode.
Data Source
AI summary
A switch arrangement is operable to, as a result of an AC power source being electrically connected with terminals of a charge port of a vehicle, configure the terminals to pass three-phase AC current for an onboard charger of the vehicle, and as a result of a DC power source being connected with some of the terminals, configure the some of the terminals to pass DC current for a traction battery of the vehicle.