Electric Vehicle Power Source System Segmentation for Charging Durability
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Solution Overview
Problem
Existing power source systems for electric vehicles that use common components for both vehicle running and external charging face durability and efficiency issues due to differing power consumption and voltage requirements, leading to increased component costs and complexity.
Innovation Solution
A power source system with separate configurations for vehicle running and external charging, utilizing distinct switches, voltage converters, and control units to isolate the systems during charging, ensuring components are optimized for their specific operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If common components are used for both vehicle running and external charging, then device complexity is reduced, but component durability and life are changed due to external charging influence
Solution Approach 1:
The power source system is divided into two independent sets of components: one set for vehicle running (first switch, first voltage converter, power control unit) and another set for external charging (second switch, second voltage converter, charger). This segmentation allows each component to be optimized for its specific operational conditions, preventing durability issues caused by external charging influence on vehicle running components.
2Ease of manufacture
If common components are used for both vehicle running and external charging, then manufacturing cost is reduced, but component life is changed due to external charging influence
Solution Approach 1:
The system uses separate components for vehicle running and external charging functions. While this increases the total number of components, each component can be designed and manufactured for its specific duty cycle and electrical characteristics, potentially extending component life by avoiding exposure to unfavorable operating conditions.
3Device complexity
If voltage of main battery is applied to vehicle running components during external charging, then system simplicity is maintained, but component durability is changed
Solution Approach 1:
The second switch is configured to disconnect the first switch, first voltage converter, and power control unit from the main battery voltage during external charging operations. This extraction of the vehicle running components from the external charging circuit prevents harmful influences on component durability while maintaining system configuration simplicity through controlled isolation.
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 approach extends the life and durability of components by preventing external charging influences and optimizing system design, improving charging efficiency and reducing power consumption.
Implementation Method 1
The charger is configured to convert electric power supplied from the external power source into electric power for charging the main power storage device
Implementation Method 2
The first voltage converter is connected between the main power supply line and the power supply line, and configured to convert an output voltage of the main power storage device into a level of an output voltage of the sub power storage device
Implementation Method 3
The second voltage converter is configured to convert an output voltage of the charger into the level of the output voltage of the sub power storage device
Data Source
AI summary
A PLG-ECU for external charging is provided separately from an HV-ECU for vehicle running, and configured to be capable of controlling external charging relays to be turned on/off. A sub DC/DC converter converting the output voltage of a charger into an auxiliary system voltage at the time of external charging is provided separately from a main DC/DC converter of large capacity used at the time of vehicle running. At the time of external charging, PLG-ECU can execute external charging without starting a vehicle running system while sub DC/DC converter can generate an auxiliary system voltage. Since external charging can be executed while system main relays each are kept turned off, a high voltage is not applied to components at the succeeding stage. Consequently, a main battery can be externally charged without exerting any influence on the durability and the life of each component of the vehicle running system.