Multi-Winding DC-DC Converter for Variable EV Charging Power
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Solution Overview
Problem
Existing electric vehicle supply stations with multiple charging points face inefficiencies due to fixed power distribution and complex, expensive hardware, which limits the ability to variably allocate charging power among charging points, leading to underutilization of resources and inability to meet actual power demands.
Innovation Solution
A supply station equipped with a DC-DC converter and transformer system for galvanic isolation, featuring multiple windings and bridge circuits with semiconductor switching elements, allows for variable distribution of charging power among charging points, eliminating the need for multiple power modules and peripherals, and enabling efficient power allocation based on vehicle demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If charging modules are used for power distribution, then power can be provided at different capacities at various charging points, but the hardware becomes complex and expensive requiring extensive modules and matrix circuitry
Solution Approach 1:
The patent merges multiple separate charging modules into a single DC-DC converter with multiple secondary windings. Instead of using multiple independent power modules with individual control circuits, the invention combines all power conversion functions into one integrated device, significantly reducing hardware complexity while maintaining the ability to provide different power capacities at multiple charging points
Solution Approach 2:
The DC-DC converter is designed with multi-functionality to serve multiple charging points simultaneously with different power requirements. A single converter unit can distribute power to multiple outlets with varying capacities, eliminating the need for separate dedicated modules for each charging point and reducing overall system complexity
2Adaptability or versatility
If charging modules are used for power distribution, then power can be varied at charging points, but the hardware requires a large amount of space and is heavy
Solution Approach 1:
By combining multiple power modules into a single DC-DC converter, the overall weight of the supply station is reduced. The integrated design eliminates redundant structural components, housing, and mounting hardware that would be required for multiple separate modules, resulting in a lighter overall system while maintaining variable power distribution capability
3Adaptability or versatility
If charging modules are used for power distribution, then power can be varied at charging points, but the hardware requires a large amount of space
Solution Approach 1:
The integration of multiple charging functions into a single DC-DC converter dramatically reduces the space required for the supply station. Instead of allocating separate physical spaces for multiple power modules and their associated control circuits, the invention consolidates all these functions into one compact unit, freeing up valuable installation space
4Productivity
If power is distributed in stages to charging points, then power can be allocated to multiple charging points, but the actual power requirement cannot be covered when power is drawn unfavorably
Solution Approach 1:
The patent implements dynamic power allocation through independent control of primary switching elements for each secondary winding. This allows the system to continuously adjust power distribution to match actual vehicle requirements in real-time, rather than being constrained by fixed stage-based allocation. The dynamic control ensures that the full power capacity is always available to meet actual demands regardless of how power is drawn across different charging points
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 optimal distribution and utilization of resources, allowing the supply station to meet power demands without gradual power distribution, reducing hardware complexity and costs, and providing redundancy for increased security and efficiency.
Implementation Method 1
a transformer system with at least one transformer for galvanic isolation of a primary side of the DC-DC converter from a secondary side of the same
Implementation Method 2
which is fed by a first inverter
Implementation Method 3
A first bridge circuit and a second bridge circuit are provided for connecting the first output winding to the first charging point on the one hand and the second output winding to the second charging point of the supply station on the other hand. The bridge circuits each have a first secondary bridge arm and a second secondary bridge arm, each first secondary bridge arm having two series-connected semiconductor switching elements
Data Source
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AI summary
The invention relates to a power supply station for providing electrical energy for electrically powered vehicles, comprising a plurality of charging points (5, 6) and a DC/DC converter with a transformer system (9) including a transformer for galvanic isolation of a primary side (1) of the DC/DC converter from a secondary side (2) thereof, wherein the transformer system (9) provides a first input winding (90) on the primary side, which is supplied by a first inverter (10), and wherein the transformer system (9) provides a first output winding (96) and a second output winding (97) on the secondary side.wherein the first output winding (96) is assigned to a first charging point (5) and the second output winding (97) to a second charging point (6), and wherein a first bridge circuit (50) is provided for connecting the first output winding (96) to the first charging point (5) and a second bridge circuit (70) is provided for connecting the second output winding (97) to the second charging point (6), each with a first secondary bridge branch (51, 71) and a second secondary bridge branch (55, 75), wherein each first secondary bridge branch (51, 71) comprises two series-connected semiconductor switching elements (52, 53, 72, 73) and each second secondary bridge branch (55, 75) comprises two series-connected semiconductor devices (56, 57, 76,77) and wherein the first output winding (96) is connected to a midpoint (54) of the first secondary bridge branch (51) and a midpoint (58) of the second secondary bridge branch (55) of the first bridge circuit (50) and the second output winding (97) is connected to a midpoint (74) of the first secondary bridge branch (71) and a midpoint (78) of the second secondary bridge branch (75) of the second bridge circuit (70).