Onboard Battery Charger Module for Multi-Input EV Charging
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Solution Overview
Problem
Certain electric vehicles are incompatible with specific types of offboard charging systems, such as direct current (DC), single-phase alternating current (AC), and three-phase AC systems, limiting their charging options.
Innovation Solution
A multi-function onboard battery charger module (OBCM) that includes a boost converter to generate a high voltage DC output from various input types, an isolation converter to electrically isolate the boost converter from the battery pack, and a battery bypass circuit to facilitate charging using different offboard charging systems, including DC, single-phase AC, and three-phase AC inputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-function onboard charger is used, then the device complexity is reduced, but the adaptability to different offboard charging systems is limited
Solution Approach 1:
The onboard charger is designed with multiple charging circuits including a first charging circuit for DC inputs, a second charging circuit for single-phase AC inputs, and a third charging circuit for three-phase AC inputs. This multi-functionality enables the single charger to interface with various offboard charging systems while managing complexity through integrated control
2Adaptability or versatility
If multiple charging circuits are integrated into one module, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The onboard charger is segmented into distinct charging circuits (first for DC, second for single-phase AC, third for three-phase AC) that can be selectively activated. Each circuit is designed independently to handle specific input types, allowing the system to manage complexity through modular segmentation while maintaining overall adaptability
3Productivity
If voltage boosting is implemented, then the power transfer efficiency improves, but the device complexity increases
Solution Approach 1:
The voltage boosting function is implemented in advance through a dedicated boosting converter that pre-conditiones the input voltage before it reaches the charging circuits. This preliminary voltage transformation ensures efficient power transfer to the battery pack while isolating the complexity of voltage conversion from the charging control logic
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
Enables charging of electric vehicle battery packs using a wide variety of offboard charging systems, ensuring compatibility and efficient power transfer regardless of the charging system type, thereby addressing compatibility issues and enhancing charging flexibility.
Implementation Method 1
a boost converter operable to boost a charging input to a boosted output
Implementation Method 2
an isolation converter operable to electrically isolate the boost converter from the battery pack and to transform the boosted output to an isolated output
Data Source
AI summary
A multi-function onboard charging module (OBCM) operable for charging a battery pack using a wide variety of offboard charging systems, such as to enable the OBCM to charge a battery pack using electrical power provided from different types of direct current (DC), single-phase alternating current (AC), and/or three-phase AC offboard charging systems.