Charging Cable Rectifier for EV Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing charging systems for electric vehicles require a rectifier integrated into the vehicle, which increases vehicle weight and complexity, especially at high charging powers, and decreases the frequency of use with the increasing availability of DC charging columns.
Innovation Solution
A versatile charging cable with a detachable first connector element for various energy sources and a rectifier integrated within the cable, allowing connection to one-phase, two-phase, or three-phase alternating current sources, eliminating the need for a vehicle-integrated charging device by using a control unit and semiconductor components for efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rectifier is integrated into the vehicle for AC charging, then power conversion capability is improved, but vehicle weight and structural complexity increase
Solution Approach 1:
The rectifier is extracted from the vehicle and integrated into the charging cable instead. This allows the vehicle to perform DC charging without an integrated rectifier, reducing vehicle weight and complexity while maintaining the ability to convert AC to DC power through the cable-based rectifier.
Solution Approach 2:
The charging cable acts as an intermediary device that performs the rectification function. Rather than the vehicle directly converting AC to DC, the cable-based rectifier serves as a mediator that prepares the power before it reaches the vehicle, eliminating the need for vehicle-integrated power conversion hardware.
2Adaptability or versatility
If a rectifier is integrated into the vehicle for AC charging, then power conversion capability is improved, but device complexity increases
Solution Approach 1:
The rectifier is extracted from the vehicle's complex internal systems and relocated to the charging cable. This extraction simplifies the vehicle's structural complexity by removing the rectifier, its cooling system connections, and associated control infrastructure, while the cable-based rectifier handles the power conversion externally.
Solution Approach 2:
The charging system is segmented into external (cable-based rectifier) and internal (vehicle charging socket) components. This segmentation allows the complex rectification function to be isolated in the cable, separating it from the vehicle's overall system architecture and reducing the vehicle's structural complexity.
3Reliability
If a vehicle-integrated charging device is used, then charging functionality is ensured, but the frequency of use decreases with increasing DC charging column availability
Solution Approach 1:
The charging cable is designed with universal functionality to support both AC charging (with rectification) and DC charging scenarios. The cable can be used with various connector types and power sources, making it adaptable to different charging infrastructures including DC columns, thereby increasing its frequency of use across multiple charging contexts.
Solution Approach 2:
The charging system becomes dynamic and adaptable based on available infrastructure. When DC columns are available, the system uses cable-based rectification for AC charging or direct DC connection; when private AC sources are available, the same cable provides rectified charging. This dynamic adaptability increases usage frequency across varying environments.
4Weight of moving object
If AC charging is implemented without a vehicle-integrated rectifier, then vehicle weight is reduced, but adaptability to different energy sources must be maintained
Solution Approach 1:
The charging cable with integrated rectifier serves as an intermediary that adapts to different energy sources externally. The cable can connect to various AC sources (single-phase, three-phase, different voltages) and perform rectification, then deliver DC power to the vehicle through a standardized connector, maintaining adaptability without adding weight to the vehicle.
Solution Approach 2:
The system maintains adaptability dynamically through the cable-based rectifier that can adjust to different input conditions (voltage, phase configuration) from various energy sources. The rectifier in the cable adapts its operation based on the connected source, while the vehicle side remains simple and unchanged, preserving versatility without increasing vehicle weight.
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 reduces vehicle weight, simplifies charging by eliminating the need for a vehicle-integrated charging device, and allows adaptation to different energy sources and regional regulations, while ensuring safe and efficient power conversion.
Implementation Method 1
an alternating current supplied at the first connector element is convertible by the rectifier into a direct current deliverable at the second connector element
Data Source
AI summary
A charging cable including a rectifier, a first connector element, and a second connector element. The first connector element is designed for connection to a vehicle-external energy source and the second connector element is designed for connection to a charging socket of a motor vehicle with an electrical traction energy accumulator. An alternating current supplied at the first connector element is convertible by the rectifier into a direct current deliverable at the second connector element. The first connector element is detachably fastened on the charging cable via an interface of the charging cable.