Split-Winding Transformer Circuit for Multi-Voltage EV Conversion
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Solution Overview
Problem
Existing electric vehicle (EV) systems require multiple DC-DC converters to accommodate different voltage outputs, leading to increased complexity and cost in the electrical architecture.
Innovation Solution
A transformer circuit with split windings and switching means that allows dynamic adjustment of voltage outputs, enabling the system to support both 800V and 400V traction systems, as well as low voltage outputs, without the need for multiple converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple DC-DC converters are used to accommodate different voltage outputs, then the system can support various voltage requirements (400V, 800V, 12V, 48V), but the device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single DC-DC converter that can output multiple voltage levels (400V, 800V, 12V, 48V) by reconfiguring the transformer windings. The converter uses switching means to connect different combinations of primary and secondary windings, allowing one device to perform the function of multiple converters would otherwise be needed
Solution Approach 2:
The patent implements dynamics through the use of switching means that can dynamically reconfigure the transformer windings during operation. The switching means selectively connects different combinations of split windings based on the required output voltage, enabling the system to adapt its electrical configuration in real-time without physical reconfiguration
2Adaptability or versatility
If multiple DC-DC converters are used to accommodate different voltage outputs, then the system can support various voltage requirements, but the manufacturing and design costs increase
Solution Approach 1:
The patent applies merging by combining multiple converter functions into a single integrated DC-DC converter unit. By merging the functionality of what would traditionally require separate converters for different voltage outputs into one device with reconfigurable transformer windings, the design cost and manufacturing complexity are reduced while maintaining the ability to support multiple voltage requirements
3Device complexity
If fixed voltage output converters are used, then the design is simpler, but the system cannot adapt to different voltage requirements for various electrical systems
Solution Approach 1:
The patent applies segmentation by dividing the transformer windings into multiple separable sections (split windings) that can be independently connected or disconnected. The primary winding is divided into first and second split windings, and the secondary winding is similarly divided, allowing selective connection through switching means to achieve different voltage outputs while maintaining a relatively simple base design
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 solution provides a flexible and re-configurable electrical system that reduces manufacturing and design costs while maintaining flexibility in electrical configuration for various applications and vehicles.
Implementation Method 1
a transformer located between the input and the output, the transformer comprising a primary winding connected to the input; and a secondary winding connected to the output
Data Source
AI summary
A transformer circuit (100) for an electric vehicle comprises an input (104); an output (106); and a transformer (108) located between the input and the output. The transformer comprises a primary winding (110) connected to the input; and a secondary winding (102) connected to the output. At least one of the primary winding and the secondary winding comprises a first split winding (112) and a second split winding (114). The first split winding is configured for carrying a higher current than the second split winding. The circuit comprises switching means (116) configured to, where the primary winding comprises the first and second split windings, selectively connect the first split winding to the input, or connect the first and second windings in series to the input, and where the secondary winding comprises the first and second split windings, selectively connect the first split winding (112) to the output (106), or connect the first and second split windings (112, 114) in series to the output.