EV Battery Charger Power Factor Corrector for Multi-Source Compatibility
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Solution Overview
Problem
Electric vehicle battery chargers face challenges in accommodating various types of commercial AC power and DC power from different regions, requiring a charger that can efficiently handle single-phase and polyphase AC power, as well as DC power from quick chargers, while maintaining a simple structure and small size.
Innovation Solution
A battery charger for electric vehicles incorporating a motor, inverter, AC power input terminal, power factor corrector with full bridge circuits, link capacitor, switch network, and controller to manage and convert AC and DC power inputs from different sources, allowing for flexible charging configurations based on regional power standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a slow charger with simple structure is used, then the penetration rate increases, but the charger cannot handle various types of AC power from different countries
Solution Approach 1:
The power factor corrector is designed to handle multiple power input configurations (single-phase AC, polyphase AC, and DC) through a unified circuit architecture. The full bridge circuits can operate in different modes depending on the input power type, making the charger universally compatible with various power sources from different countries without requiring separate charging systems.
Solution Approach 2:
The switch network dynamically reconfigures the circuit connections based on the detected power input type. The controller adjusts the switching states of the full bridge circuits to match the input power characteristics, enabling the same hardware to adaptively handle different voltage configurations and power types without manual intervention or complex external components.
2Productivity
If an onboard charger is installed to use slow charger, then charging capability is improved, but the charger size and complexity increase
Solution Approach 1:
The charging system merges the functions of multiple chargers (single-phase AC charger, polyphase AC charger, and DC charger) into a single integrated power factor corrector unit. By combining these charging capabilities in one device with shared components (full bridge circuits, link capacitor, switch network), the total volume is reduced compared to installing separate onboard chargers for each charging type.
Solution Approach 2:
The power factor corrector serves multiple charging functions simultaneously, acting as both an AC-to-DC converter and a DC-DC converter depending on the input power type. This multi-functional design eliminates the need for separate dedicated chargers for different power sources, significantly reducing the overall charger volume required in the vehicle.
3Adaptability or versatility
If the power factor corrector handles multiple power types, then adaptability is improved, but the circuit complexity increases
Solution Approach 1:
The power factor corrector circuit is segmented into modular full bridge circuit units that can be independently controlled. Each full bridge circuit can handle specific power input configurations, and the switch network selectively activates the appropriate segments based on the input power type. This modular segmentation reduces overall circuit complexity by allowing selective activation of circuit portions rather than requiring all components to handle all power types simultaneously.
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
Enables efficient charging of high voltage batteries with power from diverse AC and DC sources, ensuring compatibility with different power conditions and standards, thus enhancing the penetration rate of electric vehicles by simplifying the charger design and reducing size.
Implementation Method 1
a motor configured to generate power for driving the electric vehicle
Implementation Method 2
an inverter configured to provide the power to the motor
Implementation Method 3
a power factor corrector configured to include a plurality of full bridge circuits through which the AC power is input through the AC power input terminal
Implementation Method 4
a link capacitor configured to connect in parallel with the power factor corrector
Data Source
AI summary
Disclosed herein is a battery charger for electric vehicle includes a motor configured to generate power for driving the electric vehicle, an inverter configured to provide the power to the motor, an AC power input terminal configured to be input at least one AC power of single phase AC power and polyphaser AC power from a slow charger, a power factor corrector configured to include a plurality of full bridge circuits through which the AC power is input through the AC power input terminal, a link capacitor configured to connect in parallel with the power factor corrector, a switch network configured to include a first switch SW A provided to connect any one of a plurality of AC power input lines and a neutral line constituting the AC power input terminal with the power factor corrector, and a second switch provided to transfer one of a direct current power input from a quick charger and an alternating current power input from a slow charger to a high voltage battery and a controller configured to control the power factor corrector and the switch network according to the conditions of the AC power and the DC power.