EV Charging Power Distributor for 400 V to 800 V Battery Charging
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Solution Overview
Problem
Existing high-voltage on-board power supply architectures for electric vehicles require additional DC voltage converters for charging at different voltage levels, leading to complex and costly charging systems, especially when transitioning between 400 V and 800 V charging stations.
Innovation Solution
A charging device with a power distributor unit and a charging unit that includes switches to switch between different output configurations, allowing direct charging at 800 V or converting 400 V to 800 V, eliminating the need for additional DC contactors and simplifying the line set, using a galvanically coupled DC voltage converter integrated within the high-voltage on-board power supply architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an additional DC voltage converter is added to the charging device for charging at 400 V charging stations, then compatibility with different voltage levels is improved, but device complexity increases
Solution Approach 1:
The charging device is designed with a universal charging connection that can accept both 400 V and 800 V DC voltages. The power distributor unit includes switching circuitry that automatically detects the input voltage level and routes it appropriately, allowing the same charging device to function across multiple voltage standards without requiring separate charging units for each voltage level.
Solution Approach 2:
The patent merges the 400 V and 800 V charging paths into a single integrated charging device. The power distributor unit combines multiple input connections and output connections with switching elements that can dynamically connect either 400 V or 800 V input to the battery, eliminating the need for separate charging devices for different voltage levels.
2Adaptability or versatility
If additional DC voltage converters and contactors are added to support both 400 V and 800 V charging, then adaptability is improved, but weight increases
Solution Approach 1:
The charging device employs dynamic switching circuitry that can adapt its configuration based on the detected input voltage. The power distributor unit includes controllable switches that dynamically reconfigure the electrical connections to optimize the charging path, allowing the system to handle both 400 V and 800 V inputs with a single, optimized hardware configuration rather than requiring duplicate heavy components for each voltage level.
3Adaptability or versatility
If multiple DC voltage converters are used for voltage conversion, then compatibility with different charging standards is improved, but heat generation increases
Solution Approach 1:
The charging device performs preliminary detection of the input voltage level before initiating the charging process. The control unit detects whether the input is 400 V or 800 V and pre-configures the power distributor unit's switching elements to establish the appropriate charging path, preventing unnecessary voltage conversion operations that would generate excessive heat and ensuring optimal efficiency from the start of charging.
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 reduces the number of required plug connectors and contactors, minimizes heat generation, and simplifies installation, while ensuring compatibility with current and future charging standards, offering cost and weight savings while maintaining efficient charging capabilities.
Implementation Method 1
a charging unit (10) for converting a first DC voltage applied to the charging connection (50) into a second DC voltage, which is intended for charging the electrical energy storage (60)
Data Source
AI summary
The invention relates to a charging device (100) for charging an electrical stored energy source (60) of an electrically operable vehicle (200), said charging device comprising: a charging connection (50) for electrically connecting the charging device (100) to an external voltage supply; a charging unit (10) for converting a first DC voltage applied to the charging connection (50) into a second DC voltage which is provided for charging the electrical stored energy source (60); and a power distributor unit (30) having a first and a second output (36, 38) for providing the first DC voltage applied to the charging connection (50) and/or the second DC voltage converted by the charging unit (10) to the electrical stored energy source (60) connected to the outputs (36, 38). The power distributor unit (30) has: a first electrical connection (52) for the charging connection (50); and a second electrical connection (56) for the charging unit (10). The invention also relates to a method for charging an electrical stored energy source (60) of an electrically operable vehicle (200) using such a charging device (100).