Integrated EV Charger Topology for Wireless Power Transfer
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Solution Overview
Problem
Existing methods for integrating on-board charging (OBC) and wireless charging (WC) systems for electric vehicles result in inefficient power utilization, higher component counts, and increased costs due to low levels of integration and inefficient magnetic coupling.
Innovation Solution
The proposed solution involves an OBC device that incorporates a transformer magnetically coupled to an external wireless power transmitter, with bypass switches enabling galvanic connection between mains-side and battery-side converters, allowing for bi-directional power flow and operation at two independent frequencies without additional resonant components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional WC and OBC are integrated at DC-link level, then integration is achieved, but component count increases and integration level remains low
Solution Approach 1:
The patent merges the AC-to-DC converter of the wireless charging system with the existing AC-to-DC converter of the on-board charging system, creating a shared converter that serves both functions. This consolidation eliminates redundant components while achieving deep-level integration, directly resolving the contradiction between integration level and component count.
2Adaptability or versatility
If conventional WC and OBC are integrated at PFC level, then integration is achieved, but component count increases and power density decreases
Solution Approach 1:
The patent merges the AC-to-DC converter stages of both wireless charging and on-board charging systems into a single shared converter. This deep-level integration at the converter stage (rather than PFC level) enables better power utilization and higher power density by allowing both systems to draw power efficiently from the same conversion stage, eliminating the power density reduction seen in PFC-level integration.
3Adaptability or versatility
If magnetic integration is implemented, then integration level improves, but additional resonant components and AC switches are required
Solution Approach 1:
The patent merges the AC-to-DC converter functionality into a single shared unit that serves both wireless charging and on-board charging operations. By implementing converter-level merging rather than magnetic integration, the system achieves high integration without requiring additional resonant components or AC switches, thus improving adaptability while avoiding increased device complexity.
4Reliability
If conventional integration methods are used, then system operation is maintained, but copper utilization decreases and current stress increases
Solution Approach 1:
The patent merges the power conversion paths of wireless charging and on-board charging through a shared AC-to-DC converter. This consolidation optimizes current flow paths and copper utilization by eliminating redundant wiring and conversion stages, while maintaining reliable system operation through coordinated control of the shared converter for both charging modes.
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 configuration achieves higher power density and reduced costs by eliminating the need for additional resonant components and optimizing magnetic coupling, resulting in improved copper utilization, lower current stress, and reduced losses.
Implementation Method 1
a transformer (108) configured to be magnetically coupled to a transmitter (TX) pad of an external wireless power transmitter (WPT) such that power is received by the mains-side coil (108A) and the battery side coil (108B)
Data Source
AI summary
An on-board charging (OBC) device for an electric vehicle includes a mains input including a power factor correction (PFC) converter, a mains-side direct current-to-alternating current (DC/AC) converter, a transformer having a mains-side coil and a battery-side coil, a battery-side alternating current-to-direct current (AC/DC) converter, a battery connector and one or more bypass switches configured to galvanically connecting the mains-side converter to the battery-side converter when closed. The transformer is configured to be magnetically coupled to a transmitter (TX) pad of an external wireless power transmitter (WPT), such that power is received by the mains-side coil and the battery side coil. When the bypass switches are closed, and the transformer is magnetically coupled to a WPT, power is sent to the battery connector through both the battery-side converter and the mains-side converter.