Three-Port Charger Integrating On-Board and DCDC Modules
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Solution Overview
Problem
Existing on-board chargers for electric vehicles separate on-board chargers and high-power DCDC modules, leading to large assembly space, low conversion efficiency, and high costs due to physical assembly integration.
Innovation Solution
A three-port charger with an inversion function is designed, integrating the on-board charger and high-power DCDC module, sharing a power switch, control circuit, and magnetic core, and featuring a central control unit for flexible mode control, including charging, self-powered, and inversion modes, with a simple and compact circuit design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If on-board charger and DCDC module are separated and independently assembled, then ease of manufacture is improved, but device complexity and assembly space increase
Solution Approach 1:
The patent merges the on-board charger and DCDC module into a single integrated three-port charger device. The primary side conversion circuit handles both charging functions, while secondary side first and second conversion circuits manage high-voltage battery charging and low-voltage load power supply respectively. This consolidation reduces assembly space and simplifies the overall device structure while maintaining manufacturing feasibility through modular circuit design.
Solution Approach 2:
The integrated charger performs multiple functions through a unified device: it can charge the high-voltage battery from external power supply, power low-voltage loads from the high-voltage battery, and provide inversion function to feed power back to external power supply. The central control unit coordinates different working modes (charging mode, self-powered mode, inversion mode) to achieve versatile functionality without requiring separate independent devices.
2Ease of manufacture
If on-board charger and DCDC module are physically assembled together, then ease of manufacture is improved, but conversion efficiency decreases
Solution Approach 1:
The patent integrates both conversion functions into a single transformer with multiple windings. The primary side winding receives input from external power supply, the second winding outputs to high-voltage battery, and the third and fourth windings (connected in series) output to low-voltage load. This unified magnetic core structure reduces energy losses associated with multiple separate transformers while maintaining ease of manufacture through integrated design.
Solution Approach 2:
The patent employs a full-bridge conversion circuit topology with controllable switching elements (Q1-Q4 on primary side, Q5-Q8 on secondary side) and adjustable duty ratios. The central control unit dynamically adjusts switching frequencies and duty cycles to optimize conversion efficiency across different operating modes (charging, self-powered, inversion) and load conditions, thereby compensating for the integrated structure's potential efficiency losses.
3Volume of moving object
If on-board charger and DCDC module are integrated, then volume and weight are reduced, but device complexity increases
Solution Approach 1:
The patent combines charger and DCDC functions in one device, sharing common components including transformer, switching elements, diodes, and control circuitry. This integration directly reduces volume and weight compared to separate devices while managing complexity through functional modularity - the circuit is divided into distinct but coordinated sections (primary side conversion, secondary side first conversion, secondary side second conversion) that can be independently analyzed and maintained.
Solution Approach 2:
Despite integration, the patent maintains manageable complexity through functional segmentation. The three-port charger is divided into distinct conversion circuits: primary side conversion circuit for input processing, secondary side first conversion circuit for high-voltage battery management, and secondary side second conversion circuit for low-voltage load management. Each segment has dedicated switching elements and control logic, allowing complex functions to be organized into manageable, functionally-separated modules within a unified physical structure.
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 integration reduces volume, weight, and costs while enhancing efficiency and flexibility, enabling the charger to be widely used in on-board applications.
Implementation Method 1
a primary side conversion circuit connected with a primary side winding of a transformer, a secondary side first conversion circuit connected with a second winding of the transformer
Implementation Method 2
the switch in the primary side conversion circuit, the switch in the secondary side first conversion circuit and the switch in the secondary side second conversion circuit
Data Source
AI summary
A three-port charger with an inversion function includes a primary side conversion circuit connected with a primary side winding of a transformer, a secondary side first conversion circuit connected with a second winding of the transformer, a secondary side second conversion circuit connected with a third winding of the transformer and a fourth winding of the transformer which are connected in series, and a central control unit used for controlling switches in the primary side conversion circuit, the secondary side first conversion circuit and the secondary side second conversion circuit. The primary side conversion circuit is connected with an external power supply, the secondary side first conversion circuit is connected with a high-voltage battery. The secondary side second conversion circuit is connected with a low-voltage load. The present invention integrates the independent charger and a high-power DCDC module, and shares a power switch, a control circuit and a magnetic core.