Power Converter Load Index Evaluation for EV Charging Overload Prevention

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Solution Overview

Problem

Existing methods for determining the load index of a power converter in charging devices for electric vehicles are limited in their ability to accurately assess the dynamic operating conditions and respond effectively to changing loads.

Innovation Solution

A method and device that utilize a logging device to store multiple characteristics of the charging device and power converter, which are then evaluated by an evaluation device to determine a load index. This load index is used to trigger threshold-based notifications to superordinate decision devices, allowing for reactive adjustments to the power converter's operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple characteristics are stored and evaluated to determine load index, then measurement precision is improved, but device complexity increases

Engineering Contradiction:
Improveload index assessment accuracyVSAvoidlogging and evaluation system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The system divides the load assessment function into two separate modules: a logging device that stores multiple characteristics (voltage, current, temperature, etc.) and an evaluation device that processes these characteristics to determine the load index. This segmentation allows the system to maintain high measurement precision through comprehensive data collection while managing device complexity by distributing processing functions across separate components.

Inventive Principle:
Principle #1Segmentation

2Reliability

If dynamic real-time evaluation is performed, then reliability is improved, but use of energy increases

Engineering Contradiction:
Improvethermal overload protectionVSAvoidcomputing energy consumption
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The logging device continuously stores operating characteristics in advance, preparing the data foundation before evaluation is needed. This preliminary data collection allows the evaluation device to perform rapid real-time load index determination without requiring intensive continuous computing, thus maintaining reliable thermal overload protection while reducing energy consumption during critical evaluation moments.

Inventive Principle:
Principle #10Preliminary action

3Adaptability or versatility

If threshold-based notifications are implemented, then adaptability is improved, but device complexity increases

Engineering Contradiction:
Improvereactive operation adjustmentVSAvoidthreshold management system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system uses threshold values as adjustable parameters to trigger reactive adjustments in power converter operation. By monitoring the load index against predefined thresholds and triggering notifications when thresholds are reached, the system achieves adaptable operation without requiring complex control algorithms. The threshold parameters can be adjusted to match different operating conditions and requirements.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS20250076405A1Method and device for determining a load index of a power converter
Publication Date: 2025.03.06 SEMIKRON DANFOSS ELEKTRONIK GMBH & CO KG
  • US20250076405A1 patent drawing
  • US20250076405A1 patent drawing
  • US20250076405A1 patent drawing

AI summary

A device and a method for determining a load index of a power converter as part of a charging device for electrically operated vehicles. Included is a power converter which has power electronics switching equipment and a control device for controlling this, wherein a logging device stores a plurality, preferably at least three, particularly at least five, of characteristics of the charging device and in particular of the power converter, having an evaluation device, which evaluates the plurality of characteristics and determines the load index therefrom and, when a first threshold value of the load index is reached, transmits this information about this to a first superordinate decision device.