Integrated EV Charger and DC/DC Converter Using Shared Power Stages
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Solution Overview
Problem
Conventional battery chargers and DC/DC converters for electric vehicles often require separate components, leading to increased size, weight, and cost due to additional complex power conversion stages, which can compromise efficiency and reliability.
Innovation Solution
The integration of DC/DC converter functionality into a battery charger using shared components, repurposing existing unidirectional power conversion electronics to perform both battery charging and DC/DC conversion, with a power converter comprising multiple stages and an intermediate DC bus for adjustable voltage levels, and a controller to manage switches for concurrent operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate battery charger and DC/DC converter components are used, then functional reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the battery charger and DC/DC converter into a single integrated power conversion system. The power converter includes a rectifier stage, an intermediate DC bus, and an inverter stage that can operate in multiple modes: battery charging mode (converting AC to DC), DC/DC conversion mode (converting DC from battery to DC for vehicle loads), and bidirectional power flow mode. This integration eliminates the need for separate charger and converter components while maintaining functional reliability through a unified control system that manages power flow based on operational requirements.
Solution Approach 2:
The power converter is designed as a universal system capable of performing multiple functions: it can charge the battery from AC mains, convert battery DC to appropriate voltage levels for vehicle electrical loads, and potentially provide power to external loads. The same power conversion stages and components are used across different operating modes, maximizing resource utilization and reducing overall system complexity while maintaining reliability through proven multi-functional design.
2Adaptability or versatility
If separate battery charger and DC/DC converter components are used, then functional versatility is improved, but weight increases
Solution Approach 1:
The patent merges the battery charger and DC/DC converter into a single integrated power conversion system. The power converter includes a rectifier stage, an intermediate DC bus, and an inverter stage that can operate in multiple modes: battery charging mode (converting AC to DC), DC/DC conversion mode (converting DC from battery to DC for vehicle loads), and bidirectional power flow mode. This integration eliminates the need for separate charger and converter components while maintaining functional reliability through a unified control system that manages power flow based on operational requirements.
Solution Approach 2:
The power converter is designed as a universal system capable of performing multiple functions: it can charge the battery from AC mains, convert battery DC to appropriate voltage levels for vehicle electrical loads, and potentially provide power to external loads. The same power conversion stages and components are used across different operating modes, maximizing resource utilization and reducing overall system complexity while maintaining reliability through proven multi-functional design.
3Adaptability or versatility
If additional power conversion stages are added, then functional capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the battery charger and DC/DC converter into a single integrated power conversion system. The power converter includes a rectifier stage, an intermediate DC bus, and an inverter stage that can operate in multiple modes: battery charging mode (converting AC to DC), DC/DC conversion mode (converting DC from battery to DC for vehicle loads), and bidirectional power flow mode. This integration eliminates the need for separate charger and converter components while maintaining functional reliability through a unified control system that manages power flow based on operational requirements.
Solution Approach 2:
The power converter is designed as a universal system capable of performing multiple functions: it can charge the battery from AC mains, convert battery DC to appropriate voltage levels for vehicle electrical loads, and potentially provide power to external loads. The same power conversion stages and components are used across different operating modes, maximizing resource utilization and reducing overall system complexity while maintaining reliability through proven multi-functional design.
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 reduces the size, weight, and cost of electric vehicle electronics by leveraging shared components, enhancing efficiency and reliability while maintaining effective battery charging and DC/DC conversion capabilities.
Implementation Method 1
a rectifier operable to convert an alternating current to a direct current
Implementation Method 2
a power converter including a first stage, a second stage, and an intermediate DC voltage bus electrically coupled between the first and the second stage, the power converter operable to adjust a voltage level of a current supplied thereto
Data Source
AI summary
An apparatus and method employs a rectifier, switches, and power converter that comprises a first stage, a second stage and a direct current (DC) bus between the first and second stages, to: in a first state supply rectified DC current to the first stage and a voltage adjusted current from the second stage to a load, for example a power storage device (e.g., secondary battery, ultra-capacitor(s)) at a relatively high voltage (e.g., 48 V for traction motor), and in a second state supply DC current to the first stage from the power storage device and supply a voltage adjusted current from the second stage, for example to a lower voltage DC bus or load (e.g., 12 V). The rectifier can, for example, receive grid or mains AC power.