Parallel AC-DC Converter Modules for Cost-Effective EV Battery Charging
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Solution Overview
Problem
Existing battery chargers for electric vehicles are expensive due to the need for high-quality electronic components that can withstand high voltages and currents, and there is a need for cost-effective solutions that can efficiently charge batteries both on-board and in stationary settings.
Innovation Solution
A battery charger composed of at least three identical current-controlled AC-DC converter modules connected in parallel, with reverse current protection, allowing for the use of less expensive components and modular design that can operate with both single-phase and three-phase power sources, enabling efficient power management and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-quality electronic components are used to withstand high voltages and currents, then reliability is improved, but cost increases
Solution Approach 1:
The battery charger is divided into multiple identical AC-DC converter modules connected in parallel. Each module handles a portion of the total current, allowing the use of less expensive electronic components in each individual module while maintaining the ability to deliver high total current to charge the battery efficiently
Solution Approach 2:
The patent uses multiple identical converter modules that are copies of each other. This modular approach allows for cost-effective manufacturing through standardization and mass production of identical units, while the parallel connection of these copies enables the system to handle high currents that would otherwise require expensive specialized components
2Ease of manufacture
If multiple AC-DC converter modules are connected in parallel, then cost is reduced and power management is enhanced, but reverse current issues arise
Solution Approach 1:
The patent introduces a control unit as an intermediary that monitors and manages the operation of each parallel-connected converter module. This control unit detects reverse current conditions and coordinates the switching of modules to prevent harmful reverse current flow, enabling the cost-effective parallel modular design to operate safely and reliably
3Adaptability or versatility
If modular design with identical modules is used, then manufacturing cost is reduced and adaptability is improved, but system complexity increases
Solution Approach 1:
The patent designs identical AC-DC converter modules that can universally handle different power source configurations. Each module is capable of operating in parallel with others, allowing the system to adapt to both single-phase and three-phase power sources without requiring different module designs, thus achieving versatility through standardized multi-functional components
4Productivity
If high charging power is delivered, then charging speed is improved, but component cost and heat management become problematic
Solution Approach 1:
The patent segments the high-power charging function across multiple parallel-connected AC-DC converter modules. Each module delivers a portion of the total charging power, allowing the system to achieve high overall charging speed while using less expensive components in each individual module. The distributed architecture also helps with heat management by spreading thermal loads across multiple units
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 provides a reliable, cost-effective battery charger that can operate efficiently with both on-board and fast charging capabilities, using modular design to reduce component costs and enhance power management, allowing for flexible power sourcing and efficient charging.
Implementation Method 1
at least three identical current controlled AC-DC converter modules having reverse current protected outputs connected in parallel to a charge terminal of a vehicle battery
Data Source
AI summary
A battery charger for electric vehicles includes at least three identical current controlled AC-DC converter modules having reverse current protected outputs connected in parallel to a charge terminal of the battery.