EV Power Converter Integration With Three-Winding Transformer
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Solution Overview
Problem
Existing power conversion systems for electric vehicles require multiple DC-DC converters for OBC, LDC, and TC, leading to increased volume and cost due to the number of switches and elements.
Innovation Solution
An integrated power conversion apparatus that combines all three power conversion functions (OBC, LDC, and TC) using a first H-bridge converter, a three-winding transformer, a second H-bridge converter, an AC-DC converter, and a low voltage stage converter, with a controller managing the switching operations across various modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three separate DC-DC converters are used for OBC, LDC, and TC, then each converter can perform its specific function independently, but the number of switches and elements increases, leading to increased volume and cost
Solution Approach 1:
The patent combines three separate DC-DC converters (OBC, LDC, and TC) into a single integrated power conversion apparatus. The controller manages multiple operating modes (G2V, V2G, LDC, TC, and LDC-TC) to perform the functions of all three converters using one unified system, thereby reducing the number of switches and elements while maintaining functional independence.
Solution Approach 2:
The integrated power conversion apparatus is designed to perform multiple functions: it can charge the high-voltage battery (OBC mode), discharge to the power system (V2G mode), charge the low-voltage battery (LDC mode), drive the motor (TC mode), and simultaneously charge both batteries (LDC-TC mode). This multi-functionality eliminates the need for separate dedicated converters for each function.
2Reliability
If three separate DC-DC converters are used for OBC, LDC, and TC, then each converter can perform its specific function independently, but the number of switches and elements increases, leading to increased cost
Solution Approach 1:
The patent combines three separate DC-DC converters (OBC, LDC, and TC) into a single integrated power conversion apparatus. The controller manages multiple operating modes (G2V, V2G, LDC, TC, and LDC-TC) to perform the functions of all three converters using one unified system, thereby reducing the number of switches and elements while maintaining functional independence.
Solution Approach 2:
The integrated power conversion apparatus is designed to perform multiple functions: it can charge the high-voltage battery (OBC mode), discharge to the power system (V2G mode), charge the low-voltage battery (LDC mode), drive the motor (TC mode), and simultaneously charge both batteries (LDC-TC mode). This multi-functionality eliminates the need for separate dedicated converters for each function.
3Adaptability or versatility
If three separate DC-DC converters are used for OBC, LDC, and TC, then all power conversion functions can be performed, but the number of controllers increases, leading to increased system complexity
Solution Approach 1:
The patent combines three separate DC-DC converters (OBC, LDC, and TC) into a single integrated power conversion apparatus. The controller manages multiple operating modes (G2V, V2G, LDC, TC, and LDC-TC) to perform the functions of all three converters using one unified system, thereby reducing the number of switches and elements while maintaining functional independence.
Solution Approach 2:
The integrated power conversion apparatus is designed to perform multiple functions: it can charge the high-voltage battery (OBC mode), discharge to the power system (V2G mode), charge the low-voltage battery (LDC mode), drive the motor (TC mode), and simultaneously charge both batteries (LDC-TC mode). This multi-functionality eliminates the need for separate dedicated converters for each function.
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 integrated system reduces the number of elements and controllers, minimizing volume and cost while maintaining all necessary functions, achieving a power density increase and improved economic efficiency.
Implementation Method 1
a three-winding transformer in which a primary winding is connected to the other side of the first H-bridge converter; a second H-bridge converter with one side which is connected to a secondary winding of the three-winding transformer
Data Source
AI summary
An integrated power conversion apparatus for an electric vehicle according to the present disclosure includes a first H-bridge converter with one side connected to a high voltage battery; a three-winding transformer in which a primary winding is connected to the other side of the first H-bridge converter; a second H-bridge converter with one side which is connected to a secondary winding of the three-winding transformer; an AC-DC converter in which one side is connected to the other side of the second H-bridge converter and the other side is selectively connected to a motor or a power system; and a low voltage stage converter in which one side is selectively connected to a tertiary winding of the three-winding transformer through a selective switch and the other side is connected to a low voltage battery.