Tandem DC/DC Converter for 800V Battery Charging
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Solution Overview
Problem
Existing vehicle battery chargers face challenges in efficiently charging high-voltage batteries, particularly with 800V systems, as they require expensive components rated for 1200V, leading to increased costs and complexity.
Innovation Solution
A tandem DC/DC converter system with a primary stage and two secondary stages in series, where each stage's components are rated for a voltage less than the total output, allowing for efficient voltage generation and sharing of current, reducing the need for high-voltage components and minimizing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If components are rated for 1200V to support 800V battery charging, then the charging capability for high-voltage batteries is achieved, but the component cost and system complexity increase significantly
Solution Approach 1:
The patent divides the single high-voltage DC/DC conversion stage into two series-connected secondary stages. Each stage operates at a lower voltage (rated for 650V instead of 1200V), allowing the use of less expensive components while achieving the required total output voltage through series connection of the two stages.
Solution Approach 2:
The patent changes the voltage parameter distribution across the converter stages. Instead of one stage handling the full voltage difference, the system uses two stages with intermediate voltage levels, where each stage's components are rated for lower voltages that sum to meet the total charging requirement.
2Reliability
If components rated for 1200V are used, then reliable high-voltage charging is achieved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the voltage conversion into two series stages, each handling a portion of the total voltage, the patent enables use of lower-voltage-rated components that are more readily available and less expensive to manufacture, while maintaining system reliability through the series configuration.
Solution Approach 2:
The patent employs lower-voltage-rated components (650V rating) that are cheaper and more commercially available than 1200V-rated components, achieving cost reduction without sacrificing the required 800V charging capability through proper series stage configuration.
3Device complexity
If a single high-voltage stage is used, then the system structure is simpler, but expensive high-voltage components are required
Solution Approach 1:
The patent segments the voltage conversion function into two series-connected stages, each with standard voltage ratings. This segmentation increases structural complexity slightly but dramatically improves ease of manufacture by using commonly available lower-voltage components instead of specialized high-voltage parts.
Solution Approach 2:
The two secondary stages can be designed with standardized voltage ratings that serve multiple purposes - they can be used in various charging applications and their modular design allows for easier manufacturing and assembly using standard components rather than custom high-voltage parts.
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 enables efficient charging of high-voltage batteries with reduced component costs and complexity by utilizing components rated for lower voltages, achieving effective power transfer and meeting OEM requirements for 800V batteries.
Implementation Method 1
The transformer is operatively coupled to the primary stage, the first secondary stage, and the second secondary stage to transfer the first input voltage to the first secondary stage and the second secondary stage
Data Source
AI summary
In at least one embodiment, a charging apparatus for a vehicle is provided. The apparatus includes a power converter having a primary stage, a first secondary stage, and a second secondary stage. The primary stage is configured to receive an incoming voltage to generate a first input voltage. The first secondary stage includes a first plurality of electrical components configured to generate a first portion of an output voltage. The second secondary stage is in series with the first secondary stage and includes a second plurality of electrical components configured to generate a second portion of the output voltage. Each of the first plurality of electrical components and the second plurality of electrical components is rated to a voltage rating that is less than a total sum of the first portion and the second portion of the output voltage.