Integrated EV Charger Power Modules for Lower Component Count
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Solution Overview
Problem
Existing stationary charging stations for battery electric vehicles (BEVs) are costly due to the inclusion of numerous components, which complicates the assembly and operation.
Innovation Solution
Integration of enhanced power modules within the charging stations that combine AC/DC conversion with auxiliary functions such as user interface, cooling, and control systems, reducing the number of components by incorporating these functionalities into a single module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate components are used in stationary charging stations, then each component can be independently designed and maintained, but the overall system complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (power conversion module, control system, user interface, cooling system, and isolation monitoring device) into a single integrated power module. This merging reduces the overall number of components in the charging station while maintaining all necessary functions, directly addressing the contradiction between ease of manufacture and device complexity
Solution Approach 2:
The integrated power module serves multiple functions simultaneously: it performs AC to DC power conversion, provides user interface operations, manages cooling, controls power flow, and monitors isolation. This multi-functionality allows a single component to replace several separate components, reducing system complexity while maintaining manufacturing feasibility
2Reliability
If multiple separate components are used, then functional independence is maintained, but the charging station becomes more expensive
Solution Approach 1:
By merging multiple functions into a single integrated power module, the patent reduces the number of separate components that need to be purchased, installed, and maintained. This consolidation directly reduces system cost while the modular design within the integrated module preserves functional independence through internal separation of power conversion, control, and monitoring functions
3Use of energy by moving object
If traditional power conversion systems are used, then AC to DC conversion is achieved, but auxiliary circuits require separate power sources increasing component count
Solution Approach 1:
The integrated power module combines the main AC to DC power conversion function with the auxiliary power supply function. The power conversion circuit generates both the high voltage DC for battery charging and the low voltage DC for auxiliary circuits, eliminating the need for separate auxiliary power sources and reducing overall component count
Solution Approach 2:
The power conversion module serves itself by generating its own auxiliary power requirements internally. The same power conversion circuit that charges the battery also provides power to the control system, user interface, and cooling system, making the system self-sufficient and reducing external component requirements
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
The integrated power modules efficiently convert AC to DC power while managing auxiliary operations, thereby reducing the overall component count and enhancing the efficiency and cost-effectiveness of the charging process.
Implementation Method 1
one or more enhanced power modules, electrically coupled to the input, that convert AC voltage to direct current (DC) voltage
Implementation Method 2
a switched mode power supply (SMPS) coupled to a low voltage output for powering auxiliary circuits within the stationary battery charger
Implementation Method 3
a power factor correction (PFC) module that rectifies AC voltage received from the grid into DC voltage supplied to the SMPS and the one or more electrical cables
Data Source
AI summary
A stationary battery charger, configured to detachable couple with and charge a battery electric vehicle (BEV) battery, including an input for receiving alternating current (AC) voltage from an electrical grid; one or more electrical cables configured to detachably couple with BEVs; and one or more enhanced power modules, electrically coupled to the input, that convert AC voltage to direct current (DC) voltage, each comprising a low voltage output for powering auxiliary circuits within the stationary battery charger and a high voltage output for applying DC voltage to the BEV battery.