Power Converter with Three Booster Modules for EV On-Board Chargers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current AC-DC converters for electrical vehicle on-board chargers are complex, leading to hardware and software complexity, significant electrical and thermal losses, and high costs due to the need for multiple power factor correction and DC-DC conversion stages, which are inefficient and costly.
Innovation Solution
A power converter topology using three booster modules that can operate as power factor correction (PFC) modules, with a buffer capacitor to compensate for output ripple, allowing for sinusoidal current drawing and minimal ripple in the output current, eliminating the need for smoothing capacitors and reducing hardware complexity by using a reconfigurable design for both single-phase and three-phase operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple PFC modules and DC-DC converter stages are used, then power factor correction and voltage conversion are achieved, but hardware complexity and device complexity increase significantly
Solution Approach 1:
The patent combines multiple PFC modules (first, second, and third PFC modules) into a single integrated power converter unit with shared control circuitry and magnetic components. The modules work together in parallel to achieve power factor correction while reducing overall hardware complexity compared to separate discrete modules.
Solution Approach 2:
The power converter is designed with universal booster modules that can function both as PFC modules and as voltage conversion stages. Each module can operate independently or in combination with others, providing multiple functions (PFC, voltage boosting, power conversion) within a single device architecture.
2Power
If PFC and DC-DC conversion stages are cascaded, then voltage conversion is achieved, but electrical and thermal losses increase due to multiple switching stages
Solution Approach 1:
The patent merges the PFC function and DC-DC voltage conversion function into a single integrated stage using universal booster modules. This eliminates the need for cascaded separate PFC and DC-DC stages, thereby reducing the number of switching operations and associated electrical and thermal losses.
Solution Approach 2:
The power converter maintains continuous power transfer from input to output through the universal booster modules, avoiding the intermittent energy storage and release cycles that occur in cascaded stages. This continuous action reduces energy losses and improves thermal efficiency.
3Adaptability or versatility
If three-phase operation is supported, then versatility and adaptability improve, but device complexity and control software complexity increase
Solution Approach 1:
The power converter uses universal booster modules that can operate in both single-phase and three-phase configurations. The same basic module design handles both operating modes, providing versatility without requiring separate dedicated circuits for each phase configuration.
Solution Approach 2:
The control system dynamically configures the universal booster modules based on the detected input phase configuration. The controller can switch between single-phase and three-phase operation modes, and between series and parallel module connections, adapting to different operating conditions without increasing hardware complexity.
4Stability of the object's composition
If large buffer capacitors are used for ripple compensation, then output current stability improves, but device complexity and cost increase
Solution Approach 1:
The universal booster modules inherently provide ripple compensation through their controlled switching operation and integrated control circuits. The modules self-regulate their current output to minimize ripple, eliminating the need for large external buffer capacitors and reducing overall device complexity.
Data Source
AI summary
A power converter includes at least three booster modules for transferring power at least from an AC input side to a DC output side. Each booster module has a galvanically separated input and output, and can be operated as a power factor correction module. The input of a first booster module is connected to the input side, and its output is connected to the output side for providing a first output current to the output side. The input of a second booster module is connected to the input side, and its output is connected to a buffer capacitor for providing a second output current to the buffer capacitor. The input of a third booster module is connected to the buffer capacitor and its output is connected to the output side for providing a third output current to the output side.