Range Extender Direct Voltage Converter for Hybrid Battery Charging
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Solution Overview
Problem
Existing range extenders for hybrid vehicles driven by electric machines lack the ability to provide adjustable and efficient charging of batteries, particularly lithium-ion batteries, as they rely on direct voltage application which may not optimize energy transfer and can lead to uneven battery line charging.
Innovation Solution
A range extender system comprising a generator driven by an internal combustion engine, an n-phase rectifier, and a direct voltage converter, along with a controlled battery system that can generate and regulate n-phase alternating voltage, allowing for efficient charging of batteries through a step-down converter and semiconductor switches, ensuring balanced and adjustable charging currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If direct voltage application is used for battery charging, then the charging process is simple, but the energy transfer efficiency is not optimized and battery line charging becomes uneven
Solution Approach 1:
A direct voltage converter is introduced as an intermediary device between the generator and the battery. This converter includes a rectifier that converts AC voltage to DC voltage, and a step-down converter that adjusts the DC voltage level. This intermediary system optimizes energy transfer efficiency while maintaining controlled charging of individual battery lines, resolving the contradiction between charging simplicity and energy efficiency.
2Device complexity
If direct voltage application is used for battery charging, then the system structure is simple, but uneven battery line charging occurs
Solution Approach 1:
The battery system is segmented into multiple battery lines (first, second, and third battery lines), and the direct voltage converter is configured to charge these lines in an alternating fashion. The controller manages each battery line independently, ensuring balanced charging across all lines. This segmentation approach maintains reasonable system structure while achieving uniform battery line charging.
3Adaptability or versatility
If a direct voltage converter with step-down capability is added, then adjustable and efficient charging is achieved, but device complexity increases
Solution Approach 1:
The direct voltage converter is designed with multi-functionality, combining rectification and step-down conversion capabilities in a single integrated device. This universal converter can adapt to different charging requirements and battery configurations, providing adjustable and efficient charging while minimizing the increase in device complexity through functional integration.
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 system enables efficient and adjustable charging of batteries, extending the range of hybrid vehicles by providing a constant output current suitable for lithium-ion batteries and allowing for balanced charging of battery lines, even when the lowest instantaneous voltage is present, thereby optimizing energy transfer and vehicle range.
Implementation Method 1
a generator (104) for generating electrical energy; an internal combustion engine (102) for driving the generator (104)
Implementation Method 2
an n-phase rectifier (106) for rectifying the n generator output voltages to form a rectified output voltage
Data Source
AI summary
The disclosure relates to a range extender for a hybrid vehicle configured to be driven by an electric machine. The range extender includes a generator configured to generate electrical energy, an internal combustion engine configured to drive the generator which generates a number N of generator output voltages, and an N-phase rectifier configured to rectify the number N of generator output voltages to form a rectified output voltage. The range extender further includes a direct voltage converter configured to convert the rectified output voltage of the generator.