EV Fast Charger Filter Module Layout for Flexible DC Outputs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing quick charging stations for electric vehicles face challenges in efficiently and cost-effectively implementing inductive filtering, leading to inefficiencies and increased costs due to the need for filter levels designed for maximum performance.
Innovation Solution
The solution involves dividing the last filter level into performance modules and distributing these sub-filter levels to connection points along with the power modules, allowing for flexible adaptation of filter size to available service and reducing overall filter requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a final filter stage is located directly at each connection point before the DC output, then filtration of grid disturbances and internal interference is improved, but the total amount of filter inductance and capacitance required increases significantly
Solution Approach 1:
The final filter stage is segmented into multiple sub-filter stages, with each power module having its own sub-filter stage. These sub-filter stages are distributed across the power modules and flexibly distributed to connection points, where they are combined to form the final filter stage. This segmentation allows the filter capacity to be scaled according to actual power module configuration rather than designing for maximum capacity at each connection point.
2Reliability
If filter stages are designed for maximum power at each connection point, then filtration performance is ensured, but cost and complexity increase
Solution Approach 1:
The filter stage configuration is made dynamic and flexible through the ability to distribute sub-filter stages from power modules to connection points based on actual operational needs. The system can adapt the filter capacity at each connection point to match the number and power rating of connected power modules, rather than being fixed at maximum capacity. This dynamic configuration simplifies design while ensuring adequate filtration performance.
3Object-affected harmful factors
If multiple filter stages are provided for multiple connection points, then each connection point has adequate filtration, but the overall system requires more filter components
Solution Approach 1:
The sub-filter stages integrated into power modules serve dual purposes: they function as individual filter elements within their respective power modules and simultaneously contribute to the combined final filter stage at connection points. This multi-functionality allows the same filter components to serve both local and aggregate filtration needs, reducing the total number of filter components required in the system.
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 amount of added filter inductivity and capacity needed, potentially halving the effort required for filtering at multiple connection points, while also allowing for more efficient use of space and resources.
Implementation Method 1
the sub-filter stages inductively filter differential-mode and common-mode interference
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a fast charging station for electric vehicles, wherein the fast charging station (1) has several power modules (3), wherein the fast charging station (1) has at least one AC voltage input (5) and at least two connection points (2) as DC voltage outputs, wherein the power modules (3) are at least partially flexibly divisible among the connection points (2), wherein each of the power modules (3) has a power converter arrangement (6) for converting an AC voltage as input voltage of the fast charging station (1) into a DC voltage as output voltage of the fast charging station (1), wherein the fast charging station (1) has at least one filter stage (7) with an inductive component between the AC voltage input (5) and the connection points (2), wherein with respect to the connection points (2) one of the filter stages (7) is configured as the last inductive filter stage (7).so that no further filter stage (7) with an inductive component is installed upstream of the electric vehicle downstream of the last filter stage (7). It is proposed that the last filter stage (7) be distributed across the power modules (3), that each power module (3) has a sub-filter stage (8) of the last filter stage (7), so that the sub-filter stages (8) together with the power modules (3) are flexibly distributed across the connection points (2) and, depending on the distribution, are combined to form different last filter stages (7) per connection point (2).