Modular EV Charging Converter Layout With Fewer Disconnection Switches
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Solution Overview
Problem
Existing charging devices for electric vehicles require large lead cross sections and multiple disconnection switches due to high currents during rapid charging, leading to unnecessary element duplication and complexity in modular designs.
Innovation Solution
A charging system with a voltage converter unit and storage unit that allows full-pole disconnection via three disconnection switches, enabling the voltage converter unit to be connected via the storage unit, reducing the need for additional switches and allowing configurations with or without the converter unit, and enabling connection to different charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the voltage converter unit is directly connected to the charging station for rapid charging, then high charging currents can be achieved, but large lead cross sections and multiple disconnection switches are required
Solution Approach 1:
The storage unit serves as an intermediary component between the charging station and the voltage converter unit. During rapid charging, the storage unit directly receives high currents from the charging station through its supply terminals, bypassing the voltage converter unit. This mediator approach allows the voltage converter unit to be protected from high currents while still enabling fast charging capability in the overall system.
Solution Approach 2:
The charging system is segmented into functionally independent units: the storage unit with its own disconnection switches for direct charging connection, and the voltage converter unit with fewer disconnection switches. This segmentation allows each unit to be optimized independently - the storage unit handles high-current direct charging while the voltage converter unit handles voltage conversion tasks.
2Reliability
If multiple disconnection switches are installed in the voltage converter unit for full-pole disconnection, then safety requirements are met, but the number of components and system complexity increase
Solution Approach 1:
The disconnection functions are merged and redistributed across the storage unit and voltage converter unit. The storage unit is equipped with disconnection switches that can perform full-pole disconnection for the entire charging system, including the voltage converter unit. This consolidation reduces the total number of disconnection switches needed in the voltage converter unit while maintaining safety requirements.
Solution Approach 2:
The disconnection switches in the storage unit serve multiple functions: they disconnect the storage unit itself from the charging station, and they also disconnect the voltage converter unit from the charging station. This multi-functionality eliminates the need for separate disconnection switches in the voltage converter unit, reducing overall system complexity.
3Adaptability or versatility
If the voltage converter unit is designed as a separate module for selective installation, then flexibility is improved, but element duplication occurs in different configurations
Solution Approach 1:
The storage unit is pre-equipped with disconnection switches and supply terminals that are designed to work with both direct charging and voltage converter unit configurations. This preliminary preparation allows the system to be configured flexibly later - the voltage converter unit can be added or removed without requiring changes to the storage unit's disconnection infrastructure, eliminating element duplication.
Data Source
AI summary
A charging system comprising a voltage converter unit and a storage unit, the storage unit designed for the supply of electrical energy via two supply terminals, a storage device of the storage unit comprises two terminals disconnectably connected to the storage device supply terminals via a second and a third disconnection switch, the voltage converter unit designed as a construction unit which is separate from the storage unit and which is connected to the storage unit via three terminals, and in the connected state within the storage unit two of the three terminals are connected to the two terminals of the storage device, and the third of the three terminals is connected to one of the supply terminals, and within the voltage converter unit the third of the three terminals leads via a first disconnection switch. The voltage converter unit comprises a first voltage converter and a second voltage converter.