Integrated Converter Merging High and Low Voltage Chargers
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Solution Overview
Problem
The challenge is to reduce the weight, volume, and cost of plug-in hybrid electric vehicle (PHEV) and electric vehicle (EV) chargers while increasing their capacity, as current high-capacity chargers are bulky and expensive, which hinders consumer acceptance due to long charge times and limited driving distances.
Innovation Solution
An integrated converter system that connects a low-voltage charger with the output end of a power factor correction (PFC) device of a high-voltage charger, utilizing a buck converter or 3-level buck converter to efficiently charge both high-voltage and low-voltage batteries using commercial power sources, thereby reducing the need for additional components like rectifiers, transformers, and filters, resulting in a more compact and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the capacity of the charger is increased to reduce charge time, then the charging speed is improved, but the size and cost of materials increase proportionally
Solution Approach 1:
The patent combines the high-voltage charger and low-voltage charger into a single integrated converter unit. The low-voltage charger is connected between the PFC device output and the high-voltage charger input, allowing both charging functions to share common components such as the PFC circuit, control unit, and housing. This merging reduces the overall volume and material cost while maintaining high charging capacity.
Solution Approach 2:
The integrated converter is designed to perform multiple functions: it can charge both high-voltage and low-voltage batteries simultaneously, and the low-voltage charger can operate in dual modes (charging from commercial power source or from high-voltage battery). This multi-functionality allows a single device to replace what would traditionally require separate charging systems, reducing size and material usage.
2Productivity
If the capacity of the charger is increased to reduce charge time, then the charging speed is improved, but the cost of materials increases proportionally
Solution Approach 1:
The patent combines the high-voltage charger and low-voltage charger into a single integrated converter unit. The low-voltage charger is connected between the PFC device output and the high-voltage charger input, allowing both charging functions to share common components such as the PFC circuit, control unit, and housing. This merging reduces the overall volume and material cost while maintaining high charging capacity.
Solution Approach 2:
The integrated converter is designed to perform multiple functions: it can charge both high-voltage and low-voltage batteries simultaneously, and the low-voltage charger can operate in dual modes (charging from commercial power source or from high-voltage battery). This multi-functionality allows a single device to replace what would traditionally require separate charging systems, reducing size and material usage.
3Adaptability or versatility
If separate high-voltage charger and low-voltage charger systems are used, then each battery can be charged independently, but the overall system weight and volume increase
Solution Approach 1:
The patent combines the high-voltage charger and low-voltage charger into a single integrated converter unit. The low-voltage charger is connected between the PFC device output and the high-voltage charger input, allowing both charging functions to share common components such as the PFC circuit, control unit, and housing. This merging reduces the overall volume and material cost while maintaining high charging capacity.
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 solution effectively reduces the overall weight, volume, and price of the integrated converter system while maintaining efficient battery charging capabilities, enhancing the feasibility of PHEVs and EVs by simplifying the charger design and eliminating unnecessary components.
Implementation Method 1
When the switching element is turned on, voltage output from the PFC device may be stored in the inductor, and, when the switching element is turned off, voltage stored in the inductor may be applied to the low-voltage battery
Implementation Method 2
the converter may include a buck converter or a 3-level buck converter as a non-isolation DC-DC converter
Data Source
AI summary
An integrated converter is provided. The integrated converter includes a high-voltage charger having a power factor correction (PFC) device configured to compensate a low-frequency ripple and convert an alternating current (AC) voltage of a commercial power source into a direct current (DC) voltage. A first switching module is configured to convert the DC voltage output from the PFC device into an AC voltage and charge a high-voltage battery using the commercial power source and a low-voltage charger that is connected between the PFC device and the first switching module and the high-voltage charger configured to charge a low-voltage battery using the commercial power source or the high-voltage battery.