Multi-Input Charging Using Rotor Position Control for EV Fast Charging
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Solution Overview
Problem
Existing fast charging methods for electric vehicles are limited by the need for intermediate voltage boosting when using 500V-class infrastructure, which restricts power supply and requires complex motor and inverter-based solutions.
Innovation Solution
A multi-input charging device and method that utilizes a disconnector actuator system (DAS) to optimize rotor position of the drive motor during charging, thereby enhancing charging efficiency by calculating and adjusting for the best charging efficiency based on rotor position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If intermediate voltage boosting is used with 500V-class infrastructure, then charging power is limited and requires complex motor and inverter solutions, but if multi-input charging with rotor position optimization is used, then charging efficiency increases and infrastructure flexibility improves
Solution Approach 1:
The patent dynamically adjusts the rotor position of the drive motor during multi-input charging to optimize charging efficiency. The rotor position is changed based on calculated charging efficiency values, allowing the system to adapt to different charging conditions and infrastructure types (400V or 800V) without requiring complex intermediate voltage boosting equipment.
Solution Approach 2:
The patent changes the operational parameters of the drive motor, specifically the rotor position angle, to optimize charging performance. By calculating charging efficiency at different rotor positions and selecting the optimal position, the system achieves high charging efficiency across different infrastructure voltages without additional complex hardware.
2Adaptability or versatility
If 500V-class infrastructure is used with intermediate voltage boosting, then power supply is restricted, but if multi-input charging method is used, then both 400V and 800V infrastructure can be utilized
Solution Approach 1:
The patent enables the drive motor to serve multiple functions: both as a propulsion motor and as a voltage boosting device for multi-input charging. By utilizing the motor's coil and power conversion switch, the system can charge from both 400V and 800V infrastructure without requiring separate charging systems, achieving universal compatibility across different voltage standards.
Solution Approach 2:
The drive motor acts as an intermediary device that enables compatibility between different charging infrastructure voltages (400V and 800V) and the battery system. Through controlled rotor position adjustment, the motor mediates the power transfer, allowing the vehicle to utilize either infrastructure type without direct intermediate voltage boosting equipment.
3Loss of energy
If rotor position is optimized during multi-charging, then charging efficiency increases, but if rotor position is not optimized, then charging operates at suboptimal efficiency
Solution Approach 1:
The patent implements a feedback mechanism where the charging efficiency is calculated based on the current rotor position, and this information is used to determine the next rotor position for optimization. The system continuously monitors charging efficiency and adjusts the rotor position accordingly, creating a closed-loop control system that minimizes energy loss during charging.
Solution Approach 2:
The patent performs preliminary calculation of charging efficiency at different rotor positions before actual charging begins. By pre-determining the optimal rotor position through efficiency calculations, the system prepares the motor in advance for maximum charging efficiency, avoiding energy losses during the charging process.
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 enables efficient multi-charging by optimizing the rotor position of the drive motor, thereby increasing charging efficiency and allowing for flexible use of both 400V and 800V charging infrastructure without the need for intermediate voltage boosting.
Implementation Method 1
the motor's coil and the inverter's power conversion switch to boost voltage
Implementation Method 2
releasing coupling of a disconnector actuator system (DAS)
Data Source
AI summary
An embodiment multi-input charging device includes a disconnector actuator system (DAS) controller configured to release an engagement of a DAS in response to receipt of a multi-charging input signal, a charging efficiency calculator configured to calculate a charging efficiency of a battery according to a rotor position of a rotor of a drive motor, a rotor controller configured to change the rotor position through a motor speed control until a particular rotor position having a highest charging efficiency is detected, and a charging controller configured to start multi-charging at the particular rotor position.