PCB Switching Unit for EV Charging Power Distribution
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Solution Overview
Problem
Conventional charging devices with DC fast charging stations face increased technical requirements and costs due to the use of DC contactors for power distribution, leading to complex assembly and maintenance challenges.
Innovation Solution
An electrical circuit arrangement using a printed circuit board-based switching unit, such as a circuit board relay or power semiconductor switch, to distribute and switch the charging current, reducing complexity and assembly effort while enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If DC contactors are used to distribute charging current, then power distribution capability is improved, but device complexity and assembly effort increase
Solution Approach 1:
The patent replaces mechanical DC contactors with an electronic switching unit implemented as a printed circuit board with electronic switches. This substitution eliminates the need for bulky mechanical components while achieving the same power distribution function through electronic control, thereby reducing device complexity and assembly effort.
Solution Approach 2:
The patent integrates the switching unit directly into the printed circuit board structure, merging the switching function with the circuit board itself. This consolidation eliminates separate mechanical contactor assemblies and reduces the number of discrete components, simplifying the overall device structure.
2Power
If DC contactors are used for switching charging current, then power distribution is achieved, but assembly and maintenance effort increase
Solution Approach 1:
By replacing mechanical DC contactors with electronic switches on a printed circuit board, the patent eliminates complex mechanical assembly requirements. The electronic switching unit can be manufactured using standard PCB fabrication processes and assembled using automated surface-mount technology, significantly reducing manual assembly and maintenance effort.
3Ease of operation
If conventional contactor-based switching units are used, then charging current can be switched, but connection overhead and error potential increase
Solution Approach 1:
The patent integrates the switching unit directly into the printed circuit board, merging the switching function with the circuit board's conductor tracks and connection elements. This integration eliminates separate connection points and reduces the number of discrete connections, thereby reducing connection overhead and potential error sources.
Solution Approach 2:
The patent uses standardized printed circuit board connection elements and conductor tracks that can be precisely reproduced during manufacturing. This standardization ensures consistent, error-free connections without the variability associated with mechanical contactor assemblies.
Data Source
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AI summary
The invention relates to an arrangement (10) for integration into a charging device (1) for at least one electric vehicle, comprising: - at least one power unit (20) for providing an electric charging current, - at least one charging point (30), - at least one circuit board (40), - at least one switching unit (50) which is arranged on the circuit board (40) for switching the provided charging current, wherein the at least one switching unit (50) electrically connects the at least one power unit (20) to the at least one charging point (30) in order to transfer the provided charging current to the electric vehicle.