EV Power Converter Component Reduction
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Solution Overview
Problem
Current power converting apparatuses for electric vehicles require a large number of power semiconductor components, increasing cost, volume, and weight, while also not efficiently utilizing the battery's energy storage capacity for V2G modes.
Innovation Solution
A power converting apparatus with a reduced number of power semiconductor components, utilizing a three-phase rectifier, boost converter, low voltage converter, transformer, inverter, and a single package configuration to perform charging, driving, and V2G modes, with MOSFETs and diodes connected in series and parallel to minimize component count and optimize energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional power converting apparatus uses multiple separate power semiconductor components for charging and inverting operations, then the system can perform charging and driving functions, but the number of components increases, leading to increased volume, weight, and cost
Solution Approach 1:
The patent combines the charging converter and inverting converter into a single integrated power converting apparatus. The switching unit uses a set of switching elements that are shared between charging operations (converting AC power to DC for battery charging) and inverting operations (converting DC battery power to AC for motor driving). This merging eliminates the need for separate power semiconductor components for each function, thereby reducing component count, volume, weight, and cost while maintaining both charging and driving capabilities.
Solution Approach 2:
The switching unit is designed with multi-functionality to perform both charging and inverting operations. The same switching elements and control circuitry are used regardless of whether the system is in charging mode or motor driving mode. The controller selectively activates appropriate switching elements based on the operational mode, making the power converting apparatus a universal device that handles both power conversion directions without requiring dedicated components for each function.
2Reliability
If the power converting apparatus uses a larger number of power semiconductor components to ensure reliable operation in all modes, then the system reliability improves, but the volume and weight of the apparatus increase
Solution Approach 1:
By merging the charging and inverting functions into a single integrated apparatus with shared switching elements, the patent reduces the total weight of power semiconductor components while maintaining system reliability. The same switching unit is used for both functions, eliminating redundant components that would otherwise be needed if separate converters were used for each operation.
3Ease of manufacture
If separate charging and inverting systems are used, then each function can be optimized independently, but the overall system volume and assembly complexity increase
Solution Approach 1:
The patent merges the charging converter and inverting converter into a single compact apparatus, significantly reducing the overall system volume. The switching elements, magnetic components, and control circuitry are integrated into one unit, eliminating the need for separate housings and mounting spaces for independent charging and inverting systems.
Solution Approach 2:
The integrated apparatus achieves independent function optimization through universal design. The switching unit can be selectively configured for charging operations or inverting operations based on controller commands, allowing each function to operate independently when needed while sharing the same physical infrastructure, thereby optimizing both functions without requiring separate dedicated hardware for each.
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 reduces the number of power semiconductor components, minimizing volume, weight, and heat radiation system requirements, while enabling efficient energy storage and utilization for charging, driving, and V2G modes, simplifying assembly and reducing costs.
Implementation Method 1
a three-phase rectifier 100 which is connected to a three-phase commercial power source AC
Implementation Method 2
a boost converter 110 which is connected to an output terminal of the three-phase rectifier 100
Implementation Method 3
a transformer 130 having a primary side core which is connected to an output terminal of the low voltage converter 120
Implementation Method 4
an inverter 140 and a three-phase switching unit 160 which are connected to a secondary side core of the transformer 130
Data Source
AI summary
Provided is a power converting apparatus of an electric vehicle which reduces the number of power semiconductor components to efficiently perform charging, driving, and V2G (vehicle to grid) modes in accordance with choice by a user. The device includes a charging unit which charges commercial power into a battery; an inverting unit which supplies battery power to drive a motor; a switching unit which is connected to the motor, the charging unit, and the inverting unit to be turned on/off in accordance with a switching control signal in accordance with an operation mode selection; and a controller which provides the switching control signal to the switching unit in accordance with a mode selection signal to perform the selected mode operation.