Integrated Boost Circuit for EV Charger Voltage Regulation
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Solution Overview
Problem
Existing onboard battery chargers for electric vehicles require additional boost converters, increasing component count and complexity, which is undesirable for space and weight optimization.
Innovation Solution
An integrated boost converter system that re-uses components from the isolated DC-DC converter at stage II, eliminating the need for additional switching devices by utilizing existing transistors to perform boost functions, and includes a controller to manage various configurations for voltage regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a boost converter is added at the input of the DC-DC converter to fulfill pre-charging and provide sufficient high voltage, then the voltage regulation capability is improved, but the component count and device complexity increase
Solution Approach 1:
The patent merges the boost converter functionality with the existing isolated DC-DC converter by reusing its transformer, bridge rectifier switches, and control circuitry. The boost converter shares the transformer and uses the bridge rectifier switches as boost configuration switches, eliminating the need for separate switching devices and reducing component count while maintaining voltage regulation capability
Solution Approach 2:
The existing transformer and bridge rectifier switches are made multi-functional by configuring them to perform both their original DC-DC conversion functions and additional boost conversion functions. The transformer serves dual purposes in voltage transformation and energy storage for boost operation, while the bridge rectifier switches operate in both rectification and boost configuration modes
2Adaptability or versatility
If additional switching devices are added to implement boost functions, then the voltage conversion flexibility is improved, but the weight and space requirements increase
Solution Approach 1:
The patent combines the boost converter with the isolated DC-DC converter by reusing the transformer and bridge rectifier switches, eliminating the need for additional switching devices. This merging approach maintains voltage conversion flexibility while reducing the weight that would otherwise be added by separate boost converter components
3Adaptability or versatility
If additional switching devices are added to implement boost functions, then the voltage conversion flexibility is improved, but the space requirements increase
Solution Approach 1:
The patent merges the boost converter functionality into the existing isolated DC-DC converter structure, reusing the transformer, bridge rectifier switches, and control circuitry. This integration eliminates the need for additional space that would be required for separate boost converter components while maintaining full voltage conversion flexibility
Solution Approach 2:
The existing transformer and switches are configured to perform multiple functions including both DC-DC conversion and boost conversion. This multi-functionality allows the system to achieve voltage conversion flexibility without adding the space that would be required for dedicated boost converter components
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
Reduces component count, enhances operational flexibility, and supports a wide range of voltage and power requirements while maintaining high power density and efficiency.
Implementation Method 1
one or more transformers; a bridge driver connected to a primary side of the one or more transformers; and one or more bridge rectifiers connected to a secondary side of the one or more transformers
Implementation Method 2
a boost converter including: an inductor connected to the one or more bridge rectifier switches
Data Source
AI summary
A system comprises: a high voltage (HV) direct current (DC) to DC converter (HVDC) including: one or more transformers; a bridge driver connected to a primary side of the one or more transformers; and one or more bridge rectifiers connected to a secondary side of the one or more transformers, the one or more bridge rectifiers including one or more bridge rectifier switches; a low voltage (LV) DC to DC converter (LVDC) connected to the HVDC; and a boost converter including: an inductor connected to the one or more bridge rectifier switches; and one or more boost configuration switches operable, in combination with the one or more bridge rectifier switches, to configure the boost converter into each of a bypass configuration and a boost configuration, to regulate a voltage at the LVDC.