Integrated AC/DC and DC/DC Converter With Shared Inductor Switching
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Solution Overview
Problem
Existing electric vehicle charging systems require separate components for AC and DC power conversion, leading to increased complexity, size, and cost, as well as higher conduction and switching losses due to the need for multiple diodes and switches.
Innovation Solution
An integrated DC/DC and AC/DC converter system that shares inductors and reduces the number of elements by using a single set of switches and diodes, with a controller managing the switching operation to selectively provide AC or DC power to a load, and includes a link capacitor for temporary energy storage and a DC-DC converter unit for voltage conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate components are used for AC and DC power conversion, then power conversion functionality is achieved, but system complexity and size increase
Solution Approach 1:
The patent combines the AC/DC converter and DC/DC converter into a single integrated converter system. The converter includes a rectifier circuit for AC power conversion and a DC-DC conversion circuit for DC power conversion, both sharing common components such as the input capacitor C1, inductor L1, and control circuitry. This merging eliminates the need for separate AC/DC and DC/DC converter units, thereby reducing system complexity while maintaining both power conversion functionalities.
Solution Approach 2:
The integrated converter is designed to perform multiple functions using a single system. The converter can operate in AC/DC conversion mode when AC power is supplied, and in DC/DC conversion mode when DC power is supplied. The control circuit automatically detects the input power type and configures the converter accordingly, making the system universal and adaptable to different power sources without requiring separate dedicated converters.
2Adaptability or versatility
If separate components are used for AC and DC power conversion, then power conversion functionality is achieved, but system size increases
Solution Approach 1:
The patent merges the AC/DC converter and DC/DC converter into a single integrated unit that shares common components. The inductor L1, input capacitor C1, and control circuit are shared between both conversion modes, eliminating redundant components that would otherwise be required in separate converter systems. This integration significantly reduces the overall system volume while maintaining both AC and DC power conversion capabilities.
Solution Approach 2:
The converter system is designed as a universal platform that can handle both AC and DC input powers. By implementing a single system with configurable operation modes rather than two separate systems, the patent achieves multi-functionality with reduced size. The control circuit switches between AC/DC and DC/DC conversion modes based on the input power type, allowing one physical system to replace what would traditionally require two separate systems.
3Adaptability or versatility
If multiple diodes and switches are used, then power conversion functionality is achieved, but conduction losses and switching losses increase
Solution Approach 1:
The patent combines the power conversion circuits such that the inductor L1 and capacitor C1 are shared between AC/DC and DC/DC conversion modes. This merging reduces the total number of passive components and associated parasitic elements, thereby reducing conduction losses. The control circuit is also integrated to manage both conversion modes, reducing the number of active switching devices required compared to having separate converter systems.
4Adaptability or versatility
If multiple diodes and switches are used, then power conversion functionality is achieved, but switching losses increase
Solution Approach 1:
The patent integrates the control circuits for AC/DC and DC/DC conversion into a single unified control system. This integration reduces the total number of switching operations required and minimizes the number of semiconductor switches that need to be controlled, thereby reducing switching losses. The controller automatically adapts its switching strategy based on the input power type, optimizing performance while minimizing energy losses.
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 integration reduces the system's volume and cost, minimizes conduction losses, and improves efficiency by reducing the number of diodes and switches, while allowing for flexible power output to a load based on AC or DC input.
Implementation Method 1
a first inductor having one end connected to an AC power supply unit; a second inductor having one end connected to a DC power supply unit
Implementation Method 2
a link capacitor having one end connected to the other end of the first switch and the other end connected to the other end of the second switch, and storing the AC power-based electrical energy output from the AC power supply unit or the DC power-based electrical energy output from the DC power supply unit
Data Source
AI summary
Provided is an integrated DC/DC and AC/DC converter system including a main relay selectively connected to any one of an AC power supply unit and a DC power supply unit and a controller connecting the main relay to the AC power supply unit or the DC power supply unit. Electrical energy based on the AC power output from the AC power supply and electrical energy based on DC power output from the DC power supply unit may be selectively provided to a load.