On-Board Fast Charger Using Motor Windings for AC Fast Charging
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Solution Overview
Problem
Existing electric vehicle charging systems are hindered by the need for heavy, bulky, and expensive magnetic components that are not efficiently utilized when the vehicle is stationary, leading to increased infrastructure requirements and reduced accessibility of fast charging options.
Innovation Solution
A power electronic control system that dynamically re-deploys the electric motor for on-board AC fast charging, reducing the need for additional magnetic components by using the motor for both drive and charging functions, and integrating energy storage sources to balance energy and minimize harmonic impact on the grid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional fast charging stations are used, then fast charging capability is achieved, but heavy and bulky magnetic components are required
Solution Approach 1:
The electric motor is designed to perform dual functions: serving as both the propulsion motor during vehicle operation and as the charging motor when the vehicle is stationary. This eliminates the need for separate dedicated charging equipment, reducing weight and component count while maintaining fast charging capability.
Solution Approach 2:
The patent combines the charging function with the existing motor structure by integrating the charging control circuitry and power electronics into the motor controller. The motor windings themselves are utilized as the charging element, merging two separate functions (propulsion and charging) into a single integrated system.
2Speed
If dedicated charging equipment is installed, then fast charging is enabled, but device complexity and cost increase
Solution Approach 1:
The motor controller is programmed to switch between motor control mode and charging control mode, utilizing the same hardware infrastructure for both functions. This reduces device complexity by eliminating redundant charging equipment while maintaining fast charging capability through intelligent control.
Solution Approach 2:
The system uses its own existing motor and control infrastructure to perform the charging function, rather than requiring external specialized equipment. The motor essentially charges itself by converting electrical energy from the grid directly into the battery through its existing windings and control circuitry.
3Adaptability or versatility
If additional magnetic components are added for charging, then charging capability is improved, but weight and volume increase
Solution Approach 1:
The charging function is merged with the motor structure by using the motor windings as the charging element. This eliminates the need for additional magnetic components such as separate transformers or inductors, thereby reducing volume while maintaining charging capability.
Solution Approach 2:
The motor windings serve dual purposes: generating electromagnetic force during propulsion and functioning as the inductive element for charging when stationary. This multi-functionality eliminates the need for duplicate magnetic components, reducing overall system volume.
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 solution enables efficient, cost-effective, and lightweight on-board AC fast charging across various commercial AC voltages, reducing infrastructure needs and enhancing the availability of fast charging options by utilizing existing motor components and minimizing harmonic distortion.
Implementation Method 1
an electric motor coupled to a power source
Implementation Method 2
a power electronic control system configured for the purposes of on-board AC fast charging
Implementation Method 3
integrating energy storage sources to balance energy and minimize harmonic impact on the grid
Data Source
AI summary
An innovative power electronic control system suitable for various applications, such as for electric vehicles is provided. The system, in some embodiments, is configured for the purposes of on-board AC fast charging (e.g., single phase or multi-phase) when an object is not in use (e.g., a vehicle is stationary) and use as a drive (e.g., for a vehicle, an EV drivetrain) when in motion. The innovative power electronic control system enables, among others, the ability to obtain fast-charging from existing grid infrastructure.