Integrated Vehicle Battery Charging System with Shared Full-Bridge Circuits
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Solution Overview
Problem
Conventional vehicle battery charging systems are inefficient in terms of fuel efficiency, manufacturing cost, and space utilization due to the separate and bulky components of on-board chargers and low voltage DC-DC converters, which increase system size and weight.
Innovation Solution
A system and method integrating a first full-bridge circuit unit, a second full-bridge circuit unit, a low voltage DC converter unit, and a control unit to manage charging modes, utilizing a transformer to convert and distribute power efficiently between high voltage and low voltage batteries, reducing overall system size and improving space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate on-board charger and low voltage DC-DC converter are used, then charging function is ensured, but system size and weight increase
Solution Approach 1:
The patent combines the on-board charger and low voltage DC-DC converter into a single integrated power conversion system. The full-bridge circuit units and transformers are shared between both charging functions, eliminating duplicate components. This merging reduces overall system weight while maintaining the ability to charge both high-voltage and low-voltage batteries independently or simultaneously through controlled switching of the integrated circuitry.
2Reliability
If separate on-board charger and low voltage DC-DC converter are used, then charging function is ensured, but manufacturing cost increases
Solution Approach 1:
By integrating both charging functions into one system, the patent reduces the total number of components that need to be manufactured, assembled, and tested. The shared full-bridge circuits, transformers, and control architecture simplify the manufacturing process and reduce assembly complexity, leading to lower manufacturing costs while ensuring both charging functions are maintained.
Solution Approach 2:
The integrated power conversion system is designed to perform multiple functions: it can charge the high-voltage battery through the first full-bridge circuit unit, charge the low-voltage battery through the second full-bridge circuit unit, and potentially operate in combined charging mode. This multi-functionality eliminates the need for separate dedicated devices, reducing overall system cost.
3Reliability
If separate on-board charger and low voltage DC-DC converter are used, then charging function is ensured, but space utilization decreases
Solution Approach 1:
The patent merges the on-board charger and DC-DC converter into a single integrated unit with shared magnetic components (transformers) and power electronics (full-bridge circuits). This consolidation significantly reduces the physical space required for housing both charging functions, improving space utilization in the vehicle while maintaining full charging capability for both battery types.
4Weight of stationary object
If integrated system is used, then system size is reduced, but control complexity increases
Solution Approach 1:
The integrated system is divided into distinct functional modules: the first full-bridge circuit unit for high-voltage battery charging, the second full-bridge circuit unit for low-voltage battery charging, and shared components like transformers and rectifying units. The control unit manages each module independently through dedicated control signals, which simplifies the overall control architecture despite the integration. This segmentation allows for modular control strategies that reduce complexity compared to a fully monolithic design.
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 enhances fuel efficiency, reduces manufacturing costs, and optimizes vehicle space by simultaneously charging batteries and controlling power distribution across different modes, thereby improving the overall performance and efficiency of the vehicle battery charging process.
Implementation Method 1
a first full-bridge circuit unit configured to convert direct current (DC) power which is input externally into alternating current (AC) power
Implementation Method 2
a second full-bridge circuit unit configured to: convert the AC power output from the first full-bridge circuit unit into the DC power to charge the high voltage battery
Implementation Method 3
a rectifying unit configured to rectify the AC power output by the first full-bridge circuit unit or the second full-bridge circuit unit
Implementation Method 4
a smoothing unit configured to smooth power output from the rectifying unit
Implementation Method 5
a voltage converting unit configured to convert a voltage output from the smoothing unit to charge the low voltage battery
Data Source
AI summary
A method of controlling charge of a vehicle battery includes: determining, by a control unit, whether a high voltage battery and a low voltage battery are charged in a first charging mode, a second charging mode, or a third charging mode; and charging at least one of the high voltage battery or the low voltage battery by controlling a first full-bridge circuit unit, a second full-bridge circuit unit, and a low voltage direct current (DC) converter unit based on the determined first, second or third charging mode.