Modular Charging Apparatus for Electric Vehicles
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Solution Overview
Problem
Existing charging systems for electric vehicles are inefficient and costly due to mismatched output requirements between household/commercial power supplies and vehicle charging demands, limiting charging speed and flexibility.
Innovation Solution
A modular charging apparatus with multiple identical charging units, each equipped with AC/DC converters, DC interlink circuits, high-voltage storage, and DC/DC converters, allowing for flexible connection in series or parallel to adapt to varying demand, enabling high charging rates and voltages, and incorporating galvanic isolation to reduce component diversity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If AC charging is used at conventional sockets, then the charging device can be installed, but the charging rate is restricted to low current (16A or 32A) resulting in charging times of several hours
Solution Approach 1:
The charging system is divided into multiple independent charging units (first charging unit, second charging unit, etc.), each capable of operating independently. This segmentation allows the system to provide multiple charging paths and aggregate power output, thereby increasing overall charging rate without overloading a single circuit.
Solution Approach 2:
A high-voltage store acts as an intermediary energy buffer between the AC power supply and the vehicle battery. The high-voltage store receives power from AC sources (including high-power sources like wallboxes), stores it temporarily, and then delivers it at high current to the vehicle battery, enabling fast charging without requiring direct high-current AC connections.
2Power
If DC charging is used for fast charging, then high charging rates can be achieved, but no mains connection with sufficient output is available in many households or companies
Solution Approach 1:
The charging system is designed to accept multiple types of power inputs including conventional AC sockets, three-phase wallboxes, and other AC sources. The modular architecture with multiple charging units allows the same system to adapt to different power source configurations and deliver consistent high-power DC output regardless of the input source capabilities.
3Productivity
If additional energy stores are incorporated into charging output electronics, then charging capability is improved, but component costs and system complexity increase
Solution Approach 1:
The system uses multiple standardized charging units that can be independently configured and connected. Each unit contains necessary components (AC/DC converter, high-voltage store, DC/DC converter), but the modular design allows the system to scale from 2 to 6 or more units based on specific application needs, avoiding unnecessary complexity in smaller installations.
Solution Approach 2:
Multiple charging units are connected in parallel to combine their output capabilities. This merging approach allows the system to achieve high charging rates by aggregating the power output of individual units, while maintaining the simplicity of standardized modular components rather than requiring a completely custom high-power design.
4Power
If multiple charging units are connected in parallel, then high charging current can be achieved, but control and coordination become more complex
Solution Approach 1:
The control unit continuously monitors the state of charge, current, and voltage of the vehicle battery and dynamically adjusts the power distribution among parallel-connected charging units. This feedback control ensures optimal utilization of each unit's capacity while preventing overload, simplifying the coordination of multiple units through automated real-time adjustment rather than complex manual configuration.
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 solution overcomes power limitations, allows for dynamic voltage and current adjustments, and reduces component costs, enabling faster and more efficient charging of electric vehicle batteries while ensuring safety and adaptability to different power sources.
Implementation Method 1
each charging unit has an AC/DC converter
Implementation Method 2
a DC/DC converter, wherein the charging units can be connected up on the output side as needed
Implementation Method 3
a high-voltage store and a DC/DC converter
Data Source
AI summary
A charging apparatus for charging at least one electric energy storage, in particular of motor vehicles, comprising a plurality of charging units, each charging unit having an AC/DC converter, a DC interlink circuit, a high-voltage energy storage and a DC/DC converter, wherein the charging units can be connected up on the output side as needed.