Integrated EV Charging Module for 400V-to-800V Boost Charging
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Solution Overview
Problem
Existing solutions for charging electric vehicle batteries require additional modules like DC boost-charging converters or switchable battery packs, increasing cost, volume, and complexity, and can affect reliability and safety.
Innovation Solution
Integration of a DCBC module within an integrated dual-charge module (IDCM) that combines DCBC and OBCM functions, utilizing existing power electronics and cooling systems to support both AC and DC boost charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standalone DCBC module is added to enable 800V charging from 400V EVSE, then charging voltage compatibility is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the DCBC module with the existing OBCM into a single integrated unit. The OBCM includes both AC-DC conversion functionality and DC-DC boost conversion functionality, eliminating the need for a separate standalone DCBC module. This integration merges power conversion stages and shares common components such as control circuits, cooling systems, and housing structures.
Solution Approach 2:
The OBCM is designed to perform multiple functions: it can convert AC voltage to DC voltage for AC charging, and it can also boost DC voltage from 400V to 800V for DC fast charging. This multi-functional design allows a single device to handle both AC and DC charging modes, as well as different voltage levels, without requiring separate dedicated modules for each function.
2Adaptability or versatility
If a standalone DCBC module is added to enable 800V charging from 400V EVSE, then charging voltage compatibility is improved, but volume and cost increase
Solution Approach 1:
The patent combines the DCBC module with the existing OBCM into a single integrated unit. The OBCM includes both AC-DC conversion functionality and DC-DC boost conversion functionality, eliminating the need for a separate standalone DCBC module. This integration merges power conversion stages and shares common components such as control circuits, cooling systems, and housing structures.
Solution Approach 2:
The OBCM is designed to perform multiple functions: it can convert AC voltage to DC voltage for AC charging, and it can also boost DC voltage from 400V to 800V for DC fast charging. This multi-functional design allows a single device to handle both AC and DC charging modes, as well as different voltage levels, without requiring separate dedicated modules for each function.
3Adaptability or versatility
If switchable battery packs are used to reach 800V by connecting two 400V batteries in series, then charging capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical switching system (power relays and junction boxes required for switchable battery packs) with an electronic DC-DC boost conversion system. The DCBC module uses power electronic converters to electrically transform the voltage from 400V to 800V, eliminating the need for physical battery reconfiguration and associated mechanical components.
4Adaptability or versatility
If power relays are added for switchable battery configuration, then charging voltage flexibility is improved, but reliability decreases
Solution Approach 1:
The patent replaces the mechanical switching system (power relays and junction boxes required for switchable battery packs) with an electronic DC-DC boost conversion system. The DCBC module uses power electronic converters to electrically transform the voltage from 400V to 800V, eliminating the need for physical battery reconfiguration and associated mechanical components.
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
Significantly reduces costs and space occupation while enabling efficient charging up to 800 V, eliminating the need for standalone DCBC modules and enhancing safety and reliability.
Implementation Method 1
a power-factor-correction (PFC) circuitry (24) coupled to the EMI filter (22) to receive the filtered voltage therefrom, the PFC circuitry (24) being configured to supply, on the basis of the filtered voltage, a rectified voltage VR
Implementation Method 2
a DC-DC converter circuit (26) coupled to the first D1 and second D2 PFC output nodes to receive the rectified voltage VR therefrom, the DC-DC converter circuit being configured to supply, on the basis of the rectified voltage VR, a regulated DC-DC voltage VD
Data Source
Figure 1
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AI summary
A system (100), comprising: a charging port (10) configured to be coupled to a charging station (EVSE) so as to receive the AC supply voltage or the DC supply voltage therefrom; a first charging unit (12), comprising a positive DC input node (DC+) and a negative DC input node (DC-) for receiving the DC supply voltage, the first charging unit (12) further comprising: a positive DC output node (O+), a negative DC output node (O-), and a first booster node (DB), as well as a battery (B) having a positive battery terminal (B+) and a negative battery terminal (B-), wherein the booster node (DB) is coupled to the positive DC input node (D+), a first switch (K1) set between the positive battery terminal (B+) and the positive DC output node (O+),a second switch (K2) set between the negative battery terminal (B-) and the negative DC output node (O-), a third switch (K3) set between the positive DC input node (DC+) and the positive DC output node (O+), and a fourth switch (K4) set between the negative DC input node (DC-) and the negative DC output node (O-); and a second charging unit (20A) comprising AC input nodes (L1, L2, L3, N) coupled to the AC input port (102) and DC output nodes (HV+, HV-) coupled (14) to respective DC output nodes (O+, O-) of the first charging unit (12), and a coupling circuitry (200) and a coupling switch (202); the system (100) further comprising control circuitry (18) configured to operate the first charging unit and the second charging unit on the basis of the DC supply voltage received at the charging port having a first voltage level or a second voltage level lower than said first voltage level.