EV Charging Stations with Central Isolation and Switchable DC Regulation

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Solution Overview

Problem

Existing charging devices for electric vehicles require numerous and expensive electronic components to meet diverse power requirements while ensuring galvanic isolation and flexibility, leading to inefficiencies and high costs.

Innovation Solution

A central power electronics unit with galvanically isolating DC/DC converters is used to isolate charging stations from the mains, allowing non-galvanically isolating converters to be employed in stations, reducing component count and cost, while a computer-controlled switching matrix ensures optimal power distribution and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If galvanically isolating DC/DC converters are installed in each charging station, then safety and standard compliance are ensured, but device complexity and cost increase significantly

Engineering Contradiction:

Improvegalvanic isolation safetyVSAvoidconverter quantity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple charging stations share a single galvanically isolating DC/DC converter located in the central power electronics unit. The converter's output connects to multiple charging stations through a switching matrix, allowing one isolation device to serve multiple stations simultaneously, thereby reducing overall system complexity and cost while maintaining safety

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The central galvanically isolating DC/DC converter performs multiple functions: it provides galvanic isolation for multiple charging stations, converts DC voltage levels, and interfaces with the switching matrix to dynamically allocate power to different stations. This multi-functional design eliminates the need for separate isolating converters at each station

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If multiple rectifiers and galvanically isolating DC/DC converters are connected in parallel, then maximum charging power is achieved, but device complexity and cost increase

Engineering Contradiction:

Improvecharging power capacityVSAvoidpower electronics configuration

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

A switching matrix dynamically connects rectifiers and galvanically isolating DC/DC converters to charging stations based on real-time power demands. This dynamic allocation allows the system to scale power capacity by adding parallel components while maintaining optimal complexity through intelligent routing rather than permanent fixed connections

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The power electronics system is segmented into modular rectifier units and DC/DC converter units that can be independently configured and connected in parallel. Each module can be activated or deactivated based on power requirements, allowing scalable power capacity without proportionally increasing overall system complexity

Inventive Principle:

Principle #1Segmentation

3Device complexity

If non-galvanically isolating DC/DC converters are used in charging stations, then cost and compactness improve, but galvanic isolation must be ensured through other means

Engineering Contradiction:

Improveconverter size and costVSAvoidgalvanic isolation requirement

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The central galvanically isolating DC/DC converter acts as an intermediary between the mains power supply and the charging stations. It performs the galvanic isolation function centrally, allowing individual charging stations to use simpler non-isolating converters while still maintaining system-wide isolation through the central unit's switching matrix connection

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This design achieves a cost-effective and compact charging solution with high flexibility, efficiently managing power distribution to multiple vehicles with varying demands without overloading components.

Implementation Method 1

the central power electronics unit has one or more rectifiers (3) which convert a voltage from the mains connection (1) into a DC voltage

Methodology Applied

Scientific EffectRectification: Diode

Implementation Method 2

at least one galvanically isolating DC/DC converter (4) is connected downstream of the rectifiers (3) in the central power electronics (2)

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

the charging station (5) each has at least one non-galvanically isolating DC/DC converter (6)

Methodology Applied

Scientific EffectDC/DC conversion:

Data Source

PatentEP4631775A1Charging points with central rectifier and switchable DC voltage regulators

Publication Date: 2025.10.15 AMPERFIED GMBH

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AI summary

The invention relates to a device for charging electric vehicles (8), comprising at least one mains connection (1), central power electronics (2), and a plurality of charging stations (5), each of which is connected to the central power electronics (2) via a cable (10), wherein the central power electronics (2) has one or more rectifiers (3). The invention is characterized in that at least one galvanically isolating DC/DC converter (4) is connected downstream of the rectifiers (3) in the central power electronics (2), and in that the charging stations (5) each have at least one non-galvanically isolating DC/DC converter (6).