Stepped Voltage Boost Converter for Differential Battery Charging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional DC/DC converters used in electric vehicle charging systems are large, heavy, and expensive due to the need to process all power through a transformer with multiple taps and isolated primary and secondary windings, which is inefficient for battery-to-battery charging with varying voltage ratios.
Innovation Solution
A stepped voltage boost converter (SVBC) that uses a transformer with integrated inductor and controllable current means to adapt voltage levels, eliminating the need for isolated windings and reducing the size, mass, and cost by handling only the differential power requirement between source and recipient batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional transformer with isolated primary and secondary windings and multiple taps is used to handle all power conversion, then voltage adaptation is achieved, but the device becomes large, heavy, and expensive
Solution Approach 1:
The patent segments the power conversion function into two parts: a small transformer that handles only the differential voltage between source and recipient batteries, and the main power flow that bypasses the transformer. This segmentation allows the transformer to be much smaller while maintaining full voltage adaptation capability through coordinated operation of the transformer and switching circuitry.
Solution Approach 2:
The patent employs dynamic switching circuitry that can reconfigure the power flow path based on real-time voltage conditions. The switching elements dynamically connect or disconnect the transformer from the power path, allowing the system to adapt between different operating modes (buck, boost, or direct connection) and maintain optimal performance across varying voltage ratios.
2Adaptability or versatility
If a traditional transformer with multiple taps is used to accommodate varying voltage ratios, then versatility is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces static multi-tap transformer design with dynamic switching circuitry that can electronically adjust the transformation ratio. The switching elements can connect different windings or configurations of the transformer based on control signals, providing continuous adaptability across a wide range of voltage ratios without requiring physical taps for each possible ratio.
Solution Approach 2:
The patent designs the transformer with a universal winding configuration that can operate in multiple modes (buck, boost, or direct connection) through the switching circuitry. This universal design eliminates the need for multiple specialized transformers or multi-tap configurations, as the same transformer structure can adapt to any voltage ratio requirement through electronic control.
3Power
If all power is processed through the transformer, then complete voltage conversion is achieved, but the transformer size and material usage increase
Solution Approach 1:
The patent segments the power flow into two paths: a main power path that bypasses the transformer and carries the bulk of the power, and a differential path that goes through the transformer to handle only the voltage difference. This segmentation allows the transformer to be sized for minimal power handling while the switching circuitry manages the total power conversion requirement.
Solution Approach 2:
The patent applies partial action by having the transformer handle only the partial power requirement (the differential voltage portion) rather than processing all power. The switching circuitry supplements this partial transformation to achieve complete voltage conversion, allowing the transformer to be much smaller than a traditional design would require.
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 SVBC reduces the size, mass, and cost of the converter transformer by enabling efficient energy transfer across varying voltage ratios, minimizing transformer size and material usage, and optimizing power handling efficiency.
Implementation Method 1
The transformer has a primary and a secondary with the primary being electrically coupled to the source battery and the secondary being electrically coupled to the recipient battery
Implementation Method 2
The controllable current means exhibits an inductance that can be made lower and higher based upon when the inductance is in a boost mode and buck mode
Implementation Method 3
an electrical signal to be communicated to the transformer secondary to thereby increase the secondary voltage and therefore current flowing to the recipient battery
Data Source
AI summary
Disclosed is a stepped voltage boost converter (SVBC) for use in electric vehicle supply equipment (EVSE). The converter charges a DC recipient battery (P1) with a DC source battery (BT1). The converter has a transformer (T1), buck mode circuitry, and boost mode circuitry. The transformer has a primary coupled to the source battery and a secondary coupled to the recipient battery. The buck mode circuitry, when the recipient voltage is lower than the source voltage, enables an electrical current to flow from the source battery into the primary of the transformer. The boost mode circuitry, when the recipient voltage is higher than the source voltage, enables both (a) the current to flow from the source battery into the primary of the transformer and (b) an electrical signal to be communicated to the transformer secondary to thereby increase the secondary voltage and therefore current flowing to the recipient battery.