Integrated EV Power Conversion System Component Sharing
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Solution Overview
Problem
Existing electric vehicle power conversion systems are cumbersome due to separate on-board chargers and low voltage DC converters, which operate only in specific modes and do not share components effectively, leading to increased weight and size.
Innovation Solution
Integration of on-board chargers and low voltage DC converters, with a controller managing their operations based on charging or travel modes, allowing sharing of components and reducing the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate on-board charger and low voltage DC converter are used, then each device can operate in its specific mode, but the number of components increases leading to increased weight and size
Solution Approach 1:
The patent combines the on-board charger and low voltage DC converter into a single integrated power conversion device. The inverter unit serves dual functions: acting as an on-board charger when the vehicle is stationary and as a low voltage DC converter when the vehicle is moving. This merging eliminates the need for separate devices, reducing component count, weight, and installation space while maintaining operational reliability through controller-managed mode switching.
2Reliability
If separate on-board charger and low voltage DC converter are used, then each device can operate in its specific mode, but the number of components increases leading to increased size
Solution Approach 1:
The patent integrates the on-board charger and low voltage DC converter functions into a single inverter unit, eliminating the need for separate physical devices. The controller switches between charging mode and DC conversion mode based on vehicle state, allowing one device to fulfill both functions. This significantly reduces the installation space required in the vehicle while maintaining the ability to perform both charging and voltage conversion operations reliably.
3Reliability
If more components are used for separate devices, then each device can be optimized for its function, but the manufacturing cost increases
Solution Approach 1:
The inverter unit is designed as a universal power conversion device that can perform multiple functions: AC-DC conversion for charging when stationary, and DC-DC conversion for voltage transformation when moving. The controller intelligently switches between these modes based on vehicle state. This multi-functionality eliminates the need to manufacture and install separate optimized devices, reducing overall manufacturing cost while maintaining functional optimization through dedicated control algorithms for each mode.
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 integration reduces the weight and size of the power conversion system, facilitates easier packaging, and lowers production costs by omitting unnecessary components like power factor correction circuits.
Implementation Method 1
a second coil electromagnetically coupled to the first coil to transform the AC voltage applied to the first coil at a predetermined ratio
Data Source
AI summary
An electric power conversion system includes: an AC-DC conversion circuit converting AC charging power into DC power; a motor including a plurality of coils, one end of each being connected to a neutral point; a first switching device selectively allowing or blocking supply of output power from the AC-DC conversion circuit to the neutral point; an inverter including a plurality of motor connection terminals connected to the other ends of the coils of the motor, respectively, DC connection terminals including a positive terminal and a negative terminal, and a plurality of switching elements forming electrical connections between the DC connection terminals and the plurality of motor connection terminals; a battery connected to the DC connection terminals of the inverter; and a controller controlling operations of the AC-DC conversion circuit, the first switching device, and the inverter in accordance with whether or not the battery is charged.