EV Charger Switch Network Adapts to AC Power
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Solution Overview
Problem
Electric vehicle charging systems face challenges in efficiently charging high-capacity batteries with varying AC power sources, leading to increased size and production costs due to the need for enhanced on-board charger capacity, which in turn prolongs charging time.
Innovation Solution
A charging apparatus with a reduced-sized and simplified structure, incorporating an AC power input stage, power factor corrector, link capacitor, converter, and switch network, along with a controller that adapts to different AC input conditions, including single-phase and multi-phase, symmetric, and asymmetric power, to efficiently charge electric vehicle batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the OBC capacity is increased to charge large-capacity batteries faster, then the charging time is reduced, but the size of constituent elements and production costs increase
Solution Approach 1:
The patent implements a dynamic switching mechanism that adapts the OBC circuit configuration based on the detected AC power source type. The controller dynamically switches between single-phase and multi-phase charging modes, optimizing charging speed for each condition without requiring a permanently oversized OBC design. This resolves the contradiction by providing high-speed charging capability only when multi-phase power is available, while maintaining compact size for single-phase operation.
Solution Approach 2:
The patent changes the operational parameters of the OBC based on the AC power source type. By detecting whether single-phase or multi-phase AC power is supplied, the controller adjusts the charging current and voltage parameters accordingly. This allows the system to achieve high charging speeds with multi-phase power while operating efficiently with reduced parameters for single-phase power, avoiding the need for a permanently high-capacity OBC design.
2Adaptability or versatility
If the OBC capacity is increased to handle various types of AC power, then the adaptability to different power sources is improved, but the size and production costs increase
Solution Approach 1:
The patent designs the OBC with a universal circuit architecture that can handle both single-phase and multi-phase AC power inputs through the same hardware platform. The switch network and controller enable the single OBC unit to perform multiple functions by detecting the input power type and adjusting its operation accordingly. This eliminates the need for separate OBC designs for different power sources, achieving versatility without proportionally increasing size.
Solution Approach 2:
The patent implements dynamic detection and switching capabilities that allow the OBC to adapt its configuration in real-time based on the connected AC power source. The controller dynamically identifies whether single-phase or multi-phase power is supplied and reconfigures the switch network accordingly. This dynamic adaptability provides universal compatibility with various AC power types while maintaining a compact, unified OBC design.
3Ease of manufacture
If a simplified charger structure is used, then the production cost is reduced, but the charging capability for large-capacity batteries is limited
Solution Approach 1:
The patent employs a simplified base OBC structure that can dynamically enhance its capability when multi-phase AC power is detected. The switch network and controller enable the system to activate additional charging pathways and increase current capacity only when multi-phase power is available. This allows the manufacturer to produce a compact, cost-effective OBC design that nonetheless delivers high charging speeds when the appropriate power source is connected.
Solution Approach 2:
The patent changes the operational parameters of the simplified OBC structure based on the AC power input type. When multi-phase power is detected, the controller adjusts current and voltage parameters to maximize charging capability within the constraints of the simplified hardware. This allows the cost-effective design to achieve high productivity under optimal conditions without requiring the permanently complex architecture that would be needed for constant high-speed charging.
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 solution enables efficient charging of electric vehicle batteries with various AC power sources, reducing the size and production costs of the on-board charger while minimizing charging time, thus addressing the limitations of existing systems.
Implementation Method 1
a link capacitor to be charged using the power factor corrector
Implementation Method 2
a converter configured to connect between the link capacitor and a battery
Data Source
AI summary
Disclosed herein is a charging apparatus. The charging apparatus includes an alternating current (AC) power input stage receiving at least one AC input power from among a single-phase AC power and a multi-phase AC power. A power factor corrector has a single three-leg half bridge circuit receiving the at least one AC input power through the AC power input stage. A link capacitor is charged through the power factor corrector. A converter connects between the link capacitor and a battery. A first switch connects any one of an AC power input line and a neutral line of the AC power input stage to the power factor corrector. A second switch selectively connects the AC power input stage to the power factor corrector, or the link capacitor. A controller operates the power factor corrector and the switch network based on a received condition of the at least one AC input power.