On-Board Charger Interface Layout for Compact Multi-Output Integration
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Solution Overview
Problem
The existing vehicle-mounted charging apparatuses face challenges in optimizing the layout of electrical interfaces, leading to increased volume and costs due to the need for multiple interfaces and heat management, which complicates vehicle layout and assembly.
Innovation Solution
A vehicle-mounted charging apparatus with a centralized arrangement of electrical interfaces, including an input power interface and multiple direct current output interfaces, optimized for space utilization and safety, with staggered placement to prevent electrical interference and improved insulation, and separate coolant interfaces for heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple electrical interfaces are disposed outside the vehicle-mounted charging apparatus to meet increasing functional requirements, then the adaptability and versatility of the charging apparatus is improved, but the device complexity and volume increase
Solution Approach 1:
The patent integrates multiple electrical interfaces (input power interface, first direct current output interfaces, second direct current output interface) onto a single electrical interface mounting surface located on the housing of the charging apparatus. This merging of previously separate external interfaces into one centralized location reduces layout complexity while maintaining all necessary functional connections for power input, low-voltage output, and high-voltage output.
Solution Approach 2:
The electrical interface mounting surface serves as a universal platform that accommodates multiple types of electrical interfaces simultaneously. This multi-functional surface design allows the charging apparatus to handle various power transmission tasks (AC input, DC output to low-voltage loads, high-voltage DC output) through a single integrated interface area, improving versatility without proportionally increasing complexity.
2Adaptability or versatility
If electrical interfaces are disposed on different sides of the vehicle-mounted charging apparatus, then the adaptability for different connection scenarios is improved, but the volume of the charging apparatus increases
Solution Approach 1:
Instead of distributing electrical interfaces across multiple sides (spatial distribution in three dimensions), the patent consolidates all electrical interfaces onto a single mounting surface (two-dimensional planar arrangement). This dimensional change from spatial distribution to planar concentration reduces the overall volume requirement while maintaining connection flexibility through proper interface arrangement on the surface.
3Ease of manufacture
If the electrical interface layout is not optimized, then the ease of manufacture is maintained, but the volume of the charging apparatus becomes large leading to higher costs
Solution Approach 1:
By merging multiple electrical interfaces onto a single mounting surface, the patent reduces the overall space required for interface accommodation. This consolidation simplifies the manufacturing process by reducing the number of separate mounting locations and connections required, while the standardized interface arrangement maintains ease of assembly. The reduced volume directly contributes to lower material costs and manufacturing expenses.
Data Source
AI summary
A vehicle-mounted charging apparatus and a vehicle. The vehicle-mounted charging apparatus includes a power conversion circuit and a housing. The housing is configured to accommodate the power conversion circuit. The power conversion circuit is configured to convert an input power supply into at least one of a first direct current or a second direct current. A plurality of electrical interfaces is disposed on an electrical interface mounting surface in the housing. The plurality of electrical interfaces includes one input power interface, two first direct current output interfaces, and one second direct current output interface. The input power interface is configured to be connected to an input end of the power conversion circuit. The plurality of electrical interfaces is disposed on a same surface, so that the external interfaces are appropriately arranged and highly integrated. This facilitates a vehicle layout, improves assembly simplicity.