EV Charger Module Isolation for Mixed-Voltage Vehicle Charging
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Solution Overview
Problem
Existing electric vehicle chargers struggle to safely charge vehicles with varying voltage levels simultaneously, leading to potential fires or failures due to high voltage currents flowing into low voltage vehicles.
Innovation Solution
An electric vehicle charger equipped with power modules, a distribution blocking part, and a circuit breaker, controlled by a controller, which prevents high voltage currents from flowing to low voltage vehicles by checking the operation state of these components before allowing current flow, ensuring safe charging of vehicles with different voltage requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple power modules with different voltage levels are used to charge multiple electric vehicles simultaneously, then the charging capacity and versatility of the charger is improved, but the risk of high voltage current flowing into low voltage vehicles increases, causing safety hazards
Solution Approach 1:
The charger is divided into multiple independent power modules, each capable of operating at different voltage levels. Each power module has its own circuit breaker and control unit, allowing independent management of high voltage and low voltage charging circuits. This segmentation enables the charger to simultaneously serve vehicles with different voltage requirements while maintaining safety through isolated control of each module.
Solution Approach 2:
A controller acts as an intermediary between the power modules and the electric vehicles. The controller receives vehicle identification information, determines the required voltage level, and selectively activates appropriate power modules while blocking others through distribution blocking parts. This intermediary control mechanism prevents mismatched voltage connection by mediating between the available power sources and the specific vehicle requirements.
2Adaptability or versatility
If a distribution panel and control device are used to manage multiple charging circuits, then the charger can handle multiple vehicles, but the system complexity and difficulty of controlling voltage distribution increase
Solution Approach 1:
Instead of a single complex distribution panel, the system uses multiple simplified power modules with individual circuit breakers. Each module is a self-contained unit with standardized control interfaces, reducing the overall system complexity by breaking down the distribution function into manageable, identical building blocks that can be independently controlled.
Solution Approach 2:
The controller dynamically changes operational parameters (voltage level, current flow, module activation) based on real-time vehicle requirements. By programmatically adjusting these parameters rather than using fixed complex wiring configurations, the system achieves multi-vehicle capability with simpler hardware and more flexible software-based control.
3Reliability
If circuit breakers are installed in each power module to block current, then safety is improved by preventing overcurrent, but the device complexity and cost increase
Solution Approach 1:
Circuit breakers are integrated into each power module as a standardized safety component. This segmentation approach ensures that each module has its own overcurrent protection, preventing cascading failures and isolating faults to individual modules. The repeated use of identical circuit breaker designs across modules maintains safety while avoiding the complexity of custom protection circuits for each module.
Solution Approach 2:
Circuit breakers are pre-installed and configured in each power module before operation. This preliminary safety measure ensures that protection is already in place before any charging operation begins, automatically blocking current if abnormal conditions occur without requiring additional control actions or complex monitoring systems.
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
Ensures safe and stable charging of electric vehicles with varying voltages without risking fires or failures, providing dual protection through the distribution blocking part and circuit breaker to manage voltage differences.
Implementation Method 1
a plurality of power modules configured to convert alternating current (AC) supplied from an electric power system into direct current (DC) for electric vehicle charging
Data Source
AI summary
An electric vehicle charger includes power modules which converts alternating current into direct current and which has mutual potential differences, a distribution blocking part blocking or allowing a current flowing through an electric power line between the power modules in which outputs thereof are to be linked, a circuit breaker blocking a current flowing from the power modules to an electric vehicle connected to the electric power line, and a controller configured to control each operation of the power modules, the distribution blocking part, and the circuit breaker, the controller acquiring information on, before a current of other power modules is blocked or allowed, whether each of the power modules is individually a high or low voltage power module or information on whether at least one electric vehicle is being charged by at least one of the power modules.