Shared EMI Filter Topology for Integrated EV Power Conversion
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Solution Overview
Problem
The integration of battery current control modules (BCCMs) and inverter system controllers (ISCs) in automotive vehicles is challenged by disconnecting circuitry, leading to increased package size and material counts, which complicates electric level integration and reduces packaging efficiency.
Innovation Solution
A new circuit topology is introduced that integrates BCCMs and ISCs without high-current contactors, utilizing a shared active electromagnetic interference filter for dual-mode operation, reducing the need for additional filters and minimizing package size by directly connecting the traction battery to the AC side electromagnetic interference filter input, and incorporating high-voltage-rated buffers and sensing circuitry for active noise cancellation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disconnecting circuitry (high-current contactors) is used to integrate BCCMs and ISCs, then power conversion and control capabilities are maintained, but package size increases and packaging efficiency decreases
Solution Approach 1:
The patent merges the BCCM and ISC circuits into a single integrated circuit board, eliminating the need for separate disconnecting circuitry. The shared active electromagnetic interference filter serves both the AC/DC power converter and the isolated DC/DC power converter, reducing component count and package size while maintaining full power conversion and control capabilities through careful circuit topology design.
Solution Approach 2:
The active electromagnetic interference filter is designed to serve dual functions: filtering for the AC/DC power converter and filtering for the isolated DC/DC power converter. This multi-functional component eliminates the need for separate filters and contactors, directly addressing the contradiction by reducing package volume while preserving system reliability.
2Reliability
If additional filters and contactors are added for integration, then power conversion and control capabilities are ensured, but material counts increase and packaging efficiency is reduced
Solution Approach 1:
The patent combines multiple filtering functions into a single shared active electromagnetic interference filter, eliminating the need for additional filters and contactors. This merging approach reduces material counts while maintaining reliable power conversion and control through integrated circuit design on a single PCB.
Solution Approach 2:
The shared filter is designed with universal functionality to handle electromagnetic interference from both AC/DC conversion and DC/DC isolation processes, reducing the total quantity of materials needed while ensuring robust power conversion and control capabilities through unified filtering.
3Volume of stationary object
If BCCMs and ISCs are integrated without high-current contactors, then packaging efficiency is enhanced and package size is reduced, but circuit topology complexity increases
Solution Approach 1:
The patent replaces mechanical disconnecting circuitry (high-current contactors) with an integrated electronic circuit topology on a single PCB. This substitution reduces package size and eliminates moving parts while managing circuit complexity through careful design of the shared filter and switching arrangements for both AC/DC and DC/DC conversion functions.
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
This solution reduces package size by eliminating unnecessary filters and contactors, enhancing packaging efficiency while maintaining effective power conversion and control capabilities.
Implementation Method 1
an electromagnetic interference filter connected between the AC input and AC/DC power converter
Implementation Method 2
a transformer, a second switching bridge connected between the AC/DC power converter and transformer
Data Source
AI summary
An automotive power system includes a circuit arrangement including an AC input, an AC/DC power converter, an electromagnetic interference filter connected between the AC input and AC/DC power converter, a transformer, a first switching bridge connected between the AC/DC power converter and transformer, and a switch bank connected with a secondary side of the transformer that connects the secondary side with a second switching bridge such that the second switching bridge is connected between a traction battery and the transformer, and the switching bridges and transformer form an isolated DC/DC power converter. The system also includes one or more switches that directly connect the traction battery between the AC input and electromagnetic interference filter.