Single-Port EV Charging Path Switching for AC/DC Contactor Faults
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges with disparate charging techniques for AC and DC power sources, requiring separate ports and lacking safety and reliability, particularly due to anomalies in DC fast charge contactors leading to potential damage from direct AC power supply.
Innovation Solution
A charging system with a PathSet contactor (PSC) and controller that switches between DC and AC paths based on power type and anomaly detection, using components like diodes and switches to ensure safe and reliable charging through a single port, incorporating a 4Quadrant switch and AC/DC contactor for selective power control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate ports are used for AC and DC charging, then charging functionality is provided, but device complexity increases
Solution Approach 1:
The patent combines AC and DC charging functionalities into a single charge port by using a PathSet contactor that can switch between different charging paths. The system integrates both AC charging (through on-board charger) and DC fast charging (through DC-Link) capabilities in one unified interface, eliminating the need for separate ports while maintaining full charging adaptability
2Productivity
If DC fast charging is enabled, then charging speed is improved, but reliability decreases due to contactor anomalies
Solution Approach 1:
The patent implements a controller that continuously monitors the operational state of the Fast Charge Contactor (FCC) and uses this feedback to determine the appropriate charging path. The controller detects FCC anomalies (such as welded contacts) and automatically switches to alternative charging methods, ensuring reliable operation while maintaining fast charging capability when conditions permit
Solution Approach 2:
The system prepares alternative charging paths in advance by having both AC charging path (through on-board charger) and DC charging path (through DC-Link) ready. When FCC anomalies are detected, the system can immediately switch to the pre-prepared alternative path without interrupting charging operation, thus cushioning against potential failures
3Adaptability or versatility
If AC power is supplied through DC path, then charging is provided, but harmful effects occur due to battery damage
Solution Approach 1:
The patent introduces the PathSet contactor as an intermediary switching device that ensures proper routing of power based on its type. The controller monitors the charging path selection and ensures that AC power only flows through the AC charging path (via on-board charger) while DC power flows through the DC path (via DC-Link and FCC), preventing harmful reverse routing that could damage the battery
Data Source
AI summary
A charging system for an electric vehicle includes a charge port configured to receive electrical power, a battery contactor that is connected to terminals of a power storage device of the electric vehicle, a fast charge contactor connected in a Direct Current path between the charge port and the battery contactor, and an on-board charger connected in an Alternating Current path between the charge port and the battery contactor. The charging system further includes a PathSet Contactor that is configured to control the electrical power from the charge port to the battery contactor, and a controller that is configured to control switching of at least the PathSet Contactor and the fast charge contactor to control charging of the power storage device. A method of charging an electric vehicle using the charging system is also disclosed.