High-Frequency Transformer EV Charging for Compact Fast Charging
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Solution Overview
Problem
Current electric vehicle (EV) charging systems are bulky, expensive, and inflexible, limiting their widespread adoption due to inefficiencies in power conversion and energy storage, particularly in high-power fast charging applications.
Innovation Solution
An EV charging system that includes a plurality of converters to convert grid power to high frequency AC voltages, utilizing a high frequency transformer for electrical isolation and efficient power delivery to EV charging dispensers, with a controller managing power flow and compensation for reactive power, harmonic currents, and voltage sag, enabling direct connection to distribution grids without intervening transformers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power conversion systems are used for EV charging, then electrical isolation and voltage conversion are achieved, but the system becomes bulky and expensive
Solution Approach 1:
The patent replaces conventional low-frequency power transformers with high-frequency transformers operating at 5 kHz or more. This substitution of operating frequency fundamentally changes the size requirements of the transformer, enabling much more compact magnetic components while maintaining the essential function of electrical isolation and voltage conversion.
Solution Approach 2:
The invention changes the operating frequency parameter from conventional 50/60 Hz to high frequency (5 kHz or more). This parameter change directly reduces the size of the transformer core and windings, solving the contradiction between maintaining electrical isolation functionality and reducing system volume.
2Productivity
If higher power fast charging is implemented, then charging speed increases, but system complexity and cost increase
Solution Approach 1:
The patent divides the power conversion system into modular converter units that can be independently controlled. Each converter handles a portion of the total power, allowing the system to scale in manageable increments. This segmentation reduces overall complexity while enabling high power output through parallel operation of multiple modules.
Solution Approach 2:
The invention implements dynamic control of multiple converters that can be independently adjusted based on charging demands. The system can dynamically allocate power among converters and adjust their operation to match real-time requirements, achieving high power fast charging without permanently over-provisioning the entire system.
3Volume of stationary object
If direct grid connection is made without intervening transformers, then system size is reduced, but power quality compensation becomes more challenging
Solution Approach 1:
The patent designs the high-frequency transformer-coupled converter system to perform multiple functions simultaneously: voltage conversion, electrical isolation, and power quality compensation. By making the power conversion stage multi-functional, the system achieves direct grid connection benefits while actively managing reactive power, harmonic currents, and voltage sag through the same converter circuitry.
Solution Approach 2:
The invention implements feedback control mechanisms that monitor grid conditions and adjust converter operation in real-time. This feedback enables the system to compensate for power quality issues by dynamically adjusting the converters to counteract reactive power demands, suppress harmonics, and support voltage during sags, thereby managing the complexity of direct grid connection.
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 system provides efficient, high-power fast charging with reduced size and cost, enabling faster charging times and improved power quality while integrating energy storage and renewable energy sources, enhancing the adoption of electric vehicles.
Implementation Method 1
at least one high frequency transformer coupled to the plurality of first converters to receive the at least one second voltage and to output at least one electrically isolated high frequency AC voltage
Data Source
AI summary
In one embodiment, an EV charging system includes: a plurality of first converters to receive and convert grid power at a distribution grid voltage to at least one second voltage; a high frequency transformer coupled to the first converters to receive the at least one second voltage and output at least one high frequency AC voltage; and a plurality of port rectifiers coupled to a plurality of secondary windings of the high frequency transformer, each of the port rectifiers comprising a unidirectional AC-DC converter to receive and convert the at least one high frequency AC voltage to a DC voltage. At least some of the port rectifiers may be coupled in series to provide at least one of a charging current or a charging voltage to at least one dispenser to which at least one EV is to couple.