Motor-Inverter Reconfiguration for Fast AC EV Battery Charging
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Solution Overview
Problem
The widespread adoption of electric vehicles is hindered by the limitations of existing charging technologies, including the slow charging speeds and the high cost and complexity of DC-based EVSEs, which are necessary for faster charging but are less common than AC-based systems.
Innovation Solution
A reconfigurable traction-charging system that integrates a motor, inverter, output rectifier, configurator, and controller to switch between traction and charging modes, utilizing existing components like electric motors and multiphase inverters to enable both mechanical power delivery and high-power battery charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If DC-based EVSEs are used for fast charging, then charging speed is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent makes the onboard charger perform dual functions: it charges the battery during normal operation and transforms into a DC-DC converter to enable fast charging from AC sources. This eliminates the need for separate DC-based EVSE infrastructure while achieving fast charging capability through the vehicle's existing components.
Solution Approach 2:
Instead of using complex DC-based EVSEs to provide fast charging, the patent inverts the approach by making the onboard AC charger (a simple component) perform the fast charging function through DC-DC conversion. The roles are reversed: the simple onboard charger becomes the fast charging solution rather than requiring complex external DC equipment.
2Speed
If DC-based EVSEs are deployed for fast charging, then charging speed is improved, but manufacturing cost increases
Solution Approach 1:
The onboard charger is designed to serve multiple purposes: standard charging and fast charging conversion. By making this existing component multi-functional, the patent eliminates the need to manufacture and deploy expensive DC-based EVSEs, reducing infrastructure manufacturing costs while maintaining fast charging capability.
Solution Approach 2:
The vehicle's onboard charger serves itself by transforming into a DC-DC converter to provide fast charging without requiring external DC-based EVSEs. This self-service capability allows the vehicle to perform fast charging using its own existing components, eliminating the need for costly external fast charging infrastructure.
3Device complexity
If AC-based EVSEs are used, then device complexity is reduced, but charging speed decreases
Solution Approach 1:
The onboard charger dynamically reconfigures its circuit topology through switching elements to transform from a standard AC charging configuration into a DC-DC converter configuration. This dynamic reconfiguration allows the simple AC charger to achieve fast charging performance by changing its operational mode based on charging requirements.
Solution Approach 2:
The patent changes the operational parameters of the onboard charger by adjusting switching frequencies, voltage levels, and circuit connections to enable DC-DC conversion mode. These parameter changes allow the AC charger to operate in fast charging mode without requiring complex external DC-based EVSE infrastructure.
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 allows for rapid battery recharging using high-power switched power supplies, reduces the cost of establishing EVSEs by leveraging existing vehicle components, and addresses the limited availability of fast charging stations.
Implementation Method 1
an output rectifier electrically coupled to the inverter and the rechargeable battery. The output rectifier is adapted to convert the alternating current power to direct current power
Implementation Method 2
The configurator comprises a plurality of contactors coupled with the plurality of stator windings and the plurality of power switch devices. The controller controls the plurality of power switch devices and the plurality of contactors, so as to configure the system to operate in one of a traction mode and a charging mode
Data Source
AI summary
The present teaching relates to method and system for charging a rechargeable battery deployed in an electric apparatus. The system resides in the electric apparatus. The system comprises a motor, an inverter, an output rectifier, a configurator, and a controller. The motor comprises a stator having a plurality of stator teeth and a plurality of stator windings wounded on the plurality of stator teeth. The inverter comprises a plurality of power switch devices. The configurator has contactors coupled with the plurality of stator windings and the plurality of power switch devices. The controller controls the plurality of power switch devices and the plurality of contactors, configuring the system to operate in one of a traction mode and a charging mode, where in the charging mode a voltage and/or current regulation occurs using the plurality of power switch devices.