Integrated EV High-Voltage Electronics Box for Shared Charging
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Solution Overview
Problem
Current electric vehicle power electronics systems are not adequately integrated, leading to increased size, cost, and weight, and require separate converters for traction inverter, on-board charger, and auxiliary power modules, necessitating a more integrated solution.
Innovation Solution
A highly integrated system that combines traction inverter, on-board charger, and DC boost charger into a single electronics box, utilizing motor windings for AC and DC boost charging, and a three-port transformer for magnetic integration, with a controller managing three modes of operation based on input data to optimize power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate converters are used for traction inverter, on-board charger, and auxiliary power modules, then each component can be independently optimized and maintained, but the overall system size, cost, and weight increase
Solution Approach 1:
The patent combines multiple independent power electronics converters (traction inverter, on-board charger, auxiliary power modules) into a single integrated electronics box. This merging approach shares common components such as the DC-link capacitor, control unit, and housing structure, thereby reducing overall system weight while maintaining the functional independence of each converter through separate circuit implementations within the integrated box.
2Reliability
If separate converters are used for traction inverter, on-board charger, and auxiliary power modules, then each component can be independently optimized and maintained, but the system cost increases
Solution Approach 1:
The integration of multiple converters into a single electronics box reduces the total component count and eliminates redundant structures. Common components such as the DC-link capacitor, control unit, and housing are shared across all converter functions, leading to reduced material costs, simplified manufacturing processes, and lower assembly costs compared to implementing separate independent converter units.
3Adaptability or versatility
If multiple independent power electronics converters are implemented, then each converter can be independently designed and controlled, but the system complexity increases
Solution Approach 1:
The patent integrates multiple independent power electronics converters into a unified electronics box with a single control unit that manages all converter functions. This approach reduces system complexity by consolidating control logic, sharing common circuitry where possible, and providing a unified interface for system management, while still allowing independent design and control of each converter function through modular circuit implementations within the integrated box.
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
Reduces system size and cost while maintaining efficiency by integrating power electronics, enabling dual motor drives, scalable charging, and reducing magnetic requirements through shared components and modes of operation.
Implementation Method 1
a three-port transformer for magnetic integration
Data Source
AI summary
The disclosure provides a method of operating a system supported by an electric vehicle (EV). The method includes receiving input data from the input. When the input data is indicative of the EV being in a driving status, the method includes executing a first mode of operation causing a high voltage battery supported by the EV to supply power to one or more low voltage loads and to a motor. When the input data is indicative of the EV being connected to an alternating voltage source, the method includes executing a second mode of operation causing the motor and an inverter to behave as a two-phased interleaved PFC circuit. When the input data is indicative of the EV being connected to a direct voltage source, the method includes executing a third mode of operation causing the motor and the inverter to behave as a two-phased interleaved boost converter circuit.