Integrated On-Board Charging Device Volume Reduction
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Solution Overview
Problem
Existing on-board charging devices for new energy vehicles occupy large volumes and spaces due to separate components, which is not conducive to the lightweight and space maximization of vehicles.
Innovation Solution
An on-board integrated charging device with a voltage conversion module that integrates OBC, DC/AC, and DC/DC functions on a single circuit board, utilizing a transformer with parallel secondary windings and rectifier circuits, along with a series resonance circuit, and a current distribution calculating method that optimizes efficiency and power calculations without additional detection circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate OBC parts, separate DC/AC parts and separate DC/DC parts are used, then each function can be independently controlled and maintained, but the device occupies large volume and weight in the vehicle
Solution Approach 1:
The patent combines OBC, DC/AC, and DC/DC conversion functions into a single integrated charging device. The voltage conversion module includes a transformer with primary and secondary windings, where the primary winding connects to AC input and secondary windings provide multiple output voltages for different functions (HV terminal for power battery, LV terminal for DC loads). This merging eliminates the need for separate devices while maintaining all required functions, thereby reducing overall device weight and volume in the vehicle.
Solution Approach 2:
The integrated charging device performs multiple functions simultaneously: it provides AC to DC conversion for power battery charging (OBC function), AC to DC conversion for DC loads (DC/DC function), and can invert DC to AC for AC loads (DC/AC function). The single device with multi-functional voltage conversion module replaces what would traditionally require three separate devices, achieving universality while reducing weight and volume.
2Adaptability or versatility
If OBC and DC/AC are integrated in one part with DC/DC as separate part, then some functions are combined, but parts remain separate overall and still occupy large space
Solution Approach 1:
The patent completes the integration by combining DC/DC conversion functions into the same voltage conversion module that handles OBC and DC/AC functions. The transformer's secondary windings are configured to provide both HV output (for power battery via full-bridge rectifier) and LV output (for DC loads via half-bridge rectifier). This full integration into one physical device minimizes space occupation compared to partial integration approaches.
Solution Approach 2:
The patent uses a transformer with multiple secondary windings arranged in different configurations (full-bridge and half-bridge rectifier circuits) to achieve multiple voltage conversion functions from a single AC input. This dimensional approach to voltage conversion allows one device to perform what would traditionally require multiple separate devices, reducing the overall footprint in the vehicle.
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 device reduces volume and weight by sharing control circuits and calculating current distribution in real-time, meeting reporting requirements and enhancing vehicle efficiency.
Implementation Method 1
The voltage conversion module comprises a transformer, wherein a primary winding is arranged on one side of the transformer, and two secondary windings which are connected in parallel are arranged on the other side of the transformer
Implementation Method 2
a series resonance circuit is also arranged between the primary full-bridge rectifier circuit and the primary winding
Data Source
AI summary
The present invention discloses an on-board integrated charging device and a current distribution calculating method thereof. The on-board integrated charging device comprises a voltage conversion module. The voltage conversion module is provided with an AC terminal connected to an alternating current or an alternating current load, an HV terminal connected to a power battery and an LV terminal connected to a direct current load. When the AC terminal is idle, the LV terminal is powered by the HV terminal, and an input current of the LV terminal is an actual current of the HV terminal. According to the on-board integrated charging device, OBC, DCAC and DCDC functions can be integrated on the same circuit board, a current reporting requirement can be realized through a distribution algorithm, and the volume and weight of the whole device can be reduced.