Reconfigurable Fast-Charging Power Module for Vehicle-to-Vehicle DC/DC
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Solution Overview
Problem
Existing power electronic modules (PEMs) lack flexibility in switching between AC/DC and DC/DC operations, limiting their versatility in charging systems, particularly in vehicle-to-vehicle and grid-to-vehicle charging applications.
Innovation Solution
A PEM configured with firmware selection based on intended use, incorporating control circuitry and power conversion circuitry, including a power factor correction circuit and dual-active bridge converter, to switch between AC/DC and DC/DC operations, enabling efficient power conversion between AC and DC sources and destinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PEM is designed for a specific operation mode (AC/DC or DC/DC), then the operational reliability is improved, but the adaptability to different charging scenarios deteriorates
Solution Approach 1:
The patent implements a universal PEM platform that can perform both AC/DC and DC/DC operations by incorporating dual power factor correction circuits (PFC1 and PFC2) and a dual-active bridge converter. The system uses firmware selection to configure the same hardware for different operation modes, eliminating the need for separate dedicated devices while maintaining operational reliability through optimized mode-specific control algorithms.
2Adaptability or versatility
If a PEM is designed with multi-mode capability (both AC/DC and DC/DC), then the adaptability to different charging scenarios is improved, but the device complexity increases
Solution Approach 1:
The patent merges the functionality of separate AC/DC and DC/DC conversion systems into a single integrated PEM platform. By combining dual PFC circuits and a dual-active bridge converter with unified control circuitry, the system achieves multi-mode capability without proportionally increasing complexity. The control circuitry dynamically configures the same hardware components for different operation modes through firmware selection, reducing overall system complexity compared to having separate dedicated devices.
Solution Approach 2:
The system employs dynamic configuration through firmware selection, where the control circuitry adapts the operational state of the PFC circuits and converter based on the detected charging scenario. This dynamic reconfiguration allows the same hardware to efficiently serve multiple functions without requiring permanent complex circuitry for all possible modes, thereby managing device complexity while maintaining adaptability.
3Productivity
If separate PEMs are used for AC/DC and DC/DC operations, then the operational efficiency for each specific mode is improved, but the loss of time for device selection and switching increases
Solution Approach 1:
The patent implements preliminary configuration through firmware selection that is loaded during manufacturing or initial setup based on the intended use. This preliminary action ensures that when the PEM operates, the control algorithms and parameters are already optimized for the specific operation mode, eliminating runtime configuration delays and enabling immediate efficient operation upon power-up without requiring device selection or switching time.
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
Enables flexible and efficient power conversion for both vehicle-to-vehicle and grid-to-vehicle charging, optimizing power delivery based on the specific charging scenario, enhancing operational efficiency and adaptability.
Implementation Method 1
the PFC circuit to receive the AC power from the source, correct the power factor of the received AC power and convert the AC power to DC power
Implementation Method 2
the power converter to receive the DC power from the PFC circuit and convert the DC power to an output DC power
Data Source
AI summary
A power electronic modules (PEM) and method of manufacturing thereof are disclosed, the PEM including three input electrical terminals and two output electrical terminals. The method of manufacturing includes identifying a use of a PEM for either an alternating current (AC) to direct current (DC) operation and a DC/DC operation, selecting, using control circuitry of the PEM, one of at least two instances of firmware based on the use, and loading, by control circuitry, the selected instance of firmware to the PEM. When the use is AC/DC operation, the PEM is configured via the selected firmware to convert AC power received using the three input electrical terminals to DC power. When the use is DC/DC operation, the PEM is configured via the selected firmware to convert DC power received using two of the three input electrical terminals to DC power.