Multiport EV Charger Current Interleaving
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Solution Overview
Problem
Conventional energy storage devices in electric vehicles face limitations in rapid charging due to charger components' lifespan degradation from high current operation and current ripple, which can shorten the life of contactors and other components.
Innovation Solution
A multiport energy management system that splits and interleaves currents through multiple DC converters to manage charging, reducing current ripple and extending charger lifespan by optimizing current flow and voltage boosting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current operation is used for rapid charging, then charging speed is improved, but component lifespan deteriorates due to current ripple and thermal stress
Solution Approach 1:
The charging system is divided into multiple parallel DC converter channels (first DC converter, second DC converter, etc.). Each converter handles a portion of the total charging current, allowing the system to achieve high current operation for rapid charging while distributing thermal and electrical stress across multiple components, thereby extending overall system lifespan.
Solution Approach 2:
The patent employs interleaved periodic switching of multiple DC converters operating at different phase angles. The converters are activated in alternating sequences, creating a composite current waveform that maintains high average charging current while reducing peak current ripple through phase cancellation effects, thus protecting components from excessive thermal and electrical stress.
2Reliability
If current ripple is reduced to protect components, then component lifespan is improved, but charging efficiency may deteriorate
Solution Approach 1:
Multiple DC converter outputs are merged in parallel to form a composite charging current. The individual converter currents are phase-shifted and combined such that their ripple components cancel each other out while their average current components add up, achieving both low current ripple for component protection and high charging efficiency through constructive interference of the useful current.
Solution Approach 2:
The interleaved periodic switching of multiple converters creates a high-frequency composite waveform that maintains low effective ripple. By operating converters at phase offsets (e.g., 180 degrees apart), the system achieves continuous high current delivery with reduced ripple content, preserving both component lifespan and charging efficiency.
3Reliability
If multiple DC converters are used to reduce current ripple, then component lifespan is improved, but system complexity increases
Solution Approach 1:
The control system performs multiple functions using a unified control architecture: it manages current distribution among converters, synchronizes phase angles for ripple cancellation, monitors component status, and adjusts operating parameters dynamically. This multi-functional approach reduces the need for separate control circuits and simplifies the overall system despite using multiple converters.
Solution Approach 2:
The system dynamically adjusts operating parameters (switching frequencies, phase angles, duty cycles) of the multiple DC converters to optimize performance under different conditions. By changing these parameters in real-time based on load requirements and component status, the system maintains simplicity through adaptive control rather than requiring complex hardware for every operating scenario.
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 approach minimizes recharge time for multiple energy storage devices while enhancing the robustness and longevity of charging systems by reducing the adverse effects of high current operation and ripple current.
Implementation Method 1
a power electronic conversion system having a plurality of energy ports, the power electronic conversion system comprising a plurality of DC electrical converters
Data Source
AI summary
An energy storage and management system (ESMS) includes one or more energy storage devices configured to store electrical energy, a power electronic conversion system having a plurality of energy ports and including a plurality of DC electrical converters, and a controller configured to split a source current flowing from an electrical source that is connected to one of the plurality of energy ports into a first current and a second current, wherein the first and second currents flows respectively first and second of the plurality of DC converters, alter the first current and the second current by selectively turning on and turning off current flow to the first and second DC converters, and form a charging current by passing the first current and the second current simultaneously to a first of the one or more energy storage devices that is coupled to a second of the plurality of energy ports.