Single Power Converter for Electric Vehicle Fuel Cell and Battery Integration
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Solution Overview
Problem
Existing electric vehicle power supply systems require separate and costly power converters for fuel cells and batteries, increasing complexity and degrading electrical performance, especially when operating without external power sources.
Innovation Solution
A single power converter system incorporating a fuel cell, battery, and transformer with a primary and secondary winding configuration, allowing for simultaneous charging and powering of the traction chain from both energy sources, reducing the need for separate converters and minimizing system size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power converters are used for the fuel cell and the battery, then each power source can be independently controlled, but the cost and complexity of the traction chain increases
Solution Approach 1:
The patent combines the control of fuel cell and battery into a single power converter unit. This converter integrates multiple functions including DC-DC conversion for the battery and AC-DC conversion for the fuel cell, eliminating the need for separate power converters while maintaining independent control capability through electronic control circuits that can independently manage each power source's output.
Solution Approach 2:
The single power converter is designed with multi-functionality to handle both battery and fuel cell power sources. It includes configurable conversion circuits that can operate in different modes (DC-DC, AC-DC) and adjustable control parameters that adapt to different power source characteristics, enabling one converter to perform the roles previously requiring multiple dedicated converters.
2Reliability
If separate power converters are used for the fuel cell and the battery, then each power source can be independently controlled, but the electrical performance of the assembly degrades
Solution Approach 1:
By merging the power conversion functions into a single integrated unit, the patent reduces electrical interface losses and improves overall system efficiency. The combined converter allows for optimized power flow management and reduced electromagnetic interference compared to multiple separate converters, thereby enhancing electrical performance while maintaining independent control.
Solution Approach 2:
The single power converter acts as an intermediary that intelligently manages power flow between the fuel cell, battery, and traction motor. Through electronic control, it optimizes the interaction between power sources and the load, improving electrical performance by coordinating power delivery and reducing losses at multiple conversion stages.
3Reliability
If separate power converters are used for the fuel cell and the battery, then each power source can be independently controlled, but the size of the system increases
Solution Approach 1:
The patent merges multiple power conversion functions into a single physical unit, significantly reducing the overall system volume. By integrating DC-DC conversion, AC-DC conversion, and control circuits into one converter, the patent eliminates the space required for multiple separate converter units, mounting structures, and interconnections, thereby reducing system size while preserving independent control functionality.
4Device complexity
If a single power converter is used for both fuel cell and battery, then cost and complexity are reduced, but the converter must handle multiple power sources simultaneously
Solution Approach 1:
The single power converter is designed with universal functionality to handle multiple power sources. It includes configurable conversion circuits that can operate in different modes (DC-DC for battery, AC-DC for fuel cell) and adjustable control parameters that adapt to different power source characteristics, enabling one converter to perform the roles previously requiring multiple dedicated converters.
Solution Approach 2:
The converter employs dynamic control strategies that can adjust its operating mode and parameters in real-time based on which power source is active. The control circuit can dynamically switch between handling battery power, fuel cell power, or both simultaneously, and can adjust conversion ratios and control algorithms to optimize performance for each specific operating condition.
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
Enables efficient operation of electric vehicles by integrating fuel cells and batteries with a single power converter, reducing complexity and cost while maintaining performance, especially during high switching frequencies and when external power is not available.
Implementation Method 1
the transformer comprises a primary winding, a first secondary winding and a second secondary winding, the primary winding being connected to an output of the first conversion element and the secondary windings being connected to an input of the second conversion element
Data Source
Figure 1
Figure 2
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AI summary
An electric vehicle power supply system (2) comprises a fuel cell (FC), an electric battery (BAT), a first power conversion element (4), a second power conversion element (6), and a transformer (8). An input of the first conversion element is configured to receive a charging current or deliver a traction current. The battery is connected to the terminals of an output of the second conversion element. The fuel cell is connected in series with an inductor (LH) at a midpoint (16) of the transformer between the first and second secondary windings.