EV On-Board Charger Segmented Bridge Topology
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Solution Overview
Problem
Electric vehicles with large-capacity batteries face increased charging times, which necessitates a more efficient On Board Charger (OBC) capable of handling various AC power sources while minimizing size and production costs.
Innovation Solution
A charging apparatus with an AC power input stage, power factor corrector, link capacitor, and switch network controlled by a controller to selectively connect full bridge circuits to the battery, enabling efficient charging of electric vehicles from single-phase and multi-phase AC power sources, including symmetric and asymmetric conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If OBC capacity is increased to reduce charging time of large-capacity battery, then charging speed is improved, but size of constituent elements and production costs increase
Solution Approach 1:
The OBC is divided into multiple full bridge circuits (first full bridge circuit and second full bridge circuit) that can operate independently or in combination. This segmentation allows the system to achieve high charging capacity when needed while maintaining a compact structure by only activating additional circuits when required, rather than having all circuits permanently installed and occupied.
Solution Approach 2:
The switch network dynamically connects or disconnects full bridge circuits based on charging requirements and AC power conditions. The controller selectively activates the second full bridge circuit when high charging capacity is needed, and deactivates it when standard charging suffices, allowing the OBC to adapt its effective size and power capacity in real-time rather than being fixed at maximum capacity.
2Productivity
If OBC capacity is increased to reduce charging time, then charging speed is improved, but production costs increase
Solution Approach 1:
The second full bridge circuit serves multiple functions: it can operate independently for additional charging capacity, work in parallel with the first full bridge circuit for high-speed charging, or remain dormant when not needed. This multi-functionality allows the system to achieve high charging speed when required while avoiding the permanent cost burden of having maximum-capacity components always installed and maintained.
Solution Approach 2:
The system changes its effective capacity parameters dynamically by activating or deactivating full bridge circuits based on charging demands and AC power availability. Rather than being manufactured at fixed maximum capacity, the OBC adjusts its operational parameters in real-time, allowing cost-effective manufacturing at lower baseline capacity with the option to scale up when needed.
3Adaptability or versatility
If the OBC is designed to cope with various kinds of AC power, then adaptability is improved, but device complexity increases
Solution Approach 1:
The controller detects AC power conditions (single-phase or multi-phase, symmetric or asymmetric) in advance and pre-configures the switch network to connect appropriate full bridge circuits before charging begins. This preliminary detection and configuration simplifies the overall system by avoiding the need for complex real-time reconfiguration mechanisms, as the system prepares the appropriate circuit topology ahead of time based on detected power conditions.
Solution Approach 2:
The switch network acts as an intermediary between the AC power input stage and the full bridge circuits, selectively connecting appropriate circuits based on detected AC power conditions. This intermediary layer simplifies the design by providing a standardized interface that handles the complexity of adapting to various AC power types, rather than requiring each full bridge circuit to be directly and complexly connected to all possible AC power configurations.
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
The solution allows for rapid and efficient charging of electric vehicle batteries from diverse AC power sources, reducing charging time and maintaining a compact, cost-effective OBC design.
Implementation Method 1
a power factor corrector having a plurality of full bridge circuits configured to receive the AC input power through the AC power input stage, a link capacitor configured to be charged through the power factor corrector
Data Source
AI summary
A charging apparatus for an electric vehicle is disclosed. The charging apparatus includes an AC power input stage receiving at least one AC input power from among single-phase AC power and multi-phase AC power, a power factor corrector having full bridge circuits receiving AC input power, a link capacitor charged through the power factor corrector, a switch network having a first switch connecting any one of an AC power input line and a neutral line of the AC power input stage to the power factor corrector and at least one second switch connecting the AC power input stage to the power factor corrector or the link capacitor, and a controller controlling the power factor corrector and the switch network according to AC input power condition. The second switch includes switches selectively connecting at least one full bridge circuit to a positive(+) electrode of a battery.