EV Charging Power Circuit With DC-DC Auxiliary Supply Across 400V/800V
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Solution Overview
Problem
Existing electrical power circuits in vehicles face challenges in accommodating different charging voltages, such as 400V and 800V, while ensuring that auxiliary units can operate at their required voltages, leading to increased complexity and cost.
Innovation Solution
A flexible electrical power circuit that includes a DCDC converter capable of receiving electrical energy at either 400V or 800V and providing output voltages of 12V to 48V, allowing for simultaneous operation of high and low voltage systems regardless of the charging voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the vehicle electrical system is designed to operate at 800V for faster charging, then charging speed is improved, but compatibility with existing 400V charging stations deteriorates
Solution Approach 1:
The patent implements a dynamically reconfigurable battery pack voltage system using switching gear that can change the battery pack configuration between series (800V) and parallel (400V) connections. This dynamic adaptability allows the vehicle to operate at 800V for fast charging when available, while automatically switching to 400V compatibility mode when using existing charging infrastructure, thus resolving the contradiction between charging speed and charging station compatibility
2Power
If auxiliary units are powered directly from the 800V charging input, then power availability is improved, but the requirement for voltage conversion equipment increases complexity
Solution Approach 1:
The patent makes the DC-DC converter multi-functional by enabling it to draw power from either the battery pack or the charging input, and to output power at different voltages (400V or 800V) based on the operational mode. This universal design allows the same converter to serve multiple purposes: power conversion during normal operation, and auxiliary power supply during charging, eliminating the need for separate voltage conversion equipment and reducing overall system complexity
3Adaptability or versatility
If multiple DC-DC converters are used to provide different output voltages, then voltage flexibility is improved, but system complexity and cost increase
Solution Approach 1:
The patent implements a single DC-DC converter with reconfigurable output capability that can provide different voltages (400V or 800V) to auxiliary units depending on the charging mode and vehicle operational requirements. This is achieved through switching gear that reconfigures the converter's connection to the battery pack and charging input, allowing one converter to replace what would traditionally require multiple fixed-output converters, thereby maintaining voltage flexibility while reducing system complexity and cost
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 solution enables a re-configurable electrical system that can operate with different voltage requirements, reducing manufacturing and design costs while maintaining flexibility for various vehicle configurations.
Implementation Method 1
a DCDC converter coupled to the charging input and to an output, the output for electrically connecting the DCDC converter to an electrical bus of the vehicle for providing electrical power to one or more electrical units of the vehicle at an output voltage. The DCDC converter is configured to receive electrical energy from the charging input, and to provide electrical energy at the output voltage to the output
Data Source
AI summary
An electrical power circuit (100) is disclosed, comprising a charging input (102) for receiving electrical energy at a first or second voltage for charging a traction battery (106) of the vehicle; a battery connection terminal (104) for electrically connecting to the traction battery to supply electrical energy from the charging input for charging the traction battery at the first or second voltage and to receive electrical energy from the traction battery to power one or more traction motors (108) of the vehicle at the second voltage; and a DCDC converter (112) coupled to the charging input and to an output for connecting the DCDC converter to an electrical bus for providing power to one or more electrical units at an output voltage, the DCDC converter configured to receive electrical energy from the charging input, and to provide electrical energy at the output voltage whilst the traction battery is charged at the first voltage.