Reconfigurable Traction Inverter Charging for Faster EV Battery Charging
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Solution Overview
Problem
The charging infrastructure for electric vehicles is limited by the availability of AC-based EVSEs, which are slow, and DC-based EVSEs, while faster, are technologically complex and expensive, hindering widespread adoption of electric vehicles.
Innovation Solution
A reconfigurable onboard traction-charging system that combines a motor with stator windings and a multiphase inverter, allowing switching between traction and charging modes, utilizing existing components to provide high-power charging and reduce the need for external charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If AC-based EVSEs are used for charging, then the charging infrastructure is more widely available and simpler, but the charging speed is slow
Solution Approach 1:
The patent applies multi-functionality by enabling the vehicle's onboard charger to operate in two modes: traditional AC charging mode and high-power DC charging mode. The system can function as both an AC EVSE (receiving AC power from grid) and a DC EVSE (providing DC power to battery), eliminating the need for separate charging infrastructure and achieving fast charging using existing vehicle components
Solution Approach 2:
The patent implements dynamics through a reconfigurable power conversion system that can dynamically switch between different operating modes. The onboard charger's power conversion circuitry is designed to be reconfigurable, allowing it to adapt its topology and control strategy based on whether it is charging from AC or DC sources, thereby optimizing performance for each mode
2Productivity
If DC-based EVSEs are used for charging, then the charging speed is fast, but the technology is complex and expensive
Solution Approach 1:
The patent applies self-service by utilizing the vehicle's existing onboard charger components to provide high-power DC charging functionality. Instead of requiring a complex external DC EVSE, the system uses the vehicle's own power conversion equipment, controlled by its existing charger controller, to perform high-power charging, thereby reducing external infrastructure complexity and cost
Solution Approach 2:
The patent merges the functions of the onboard charger and the power conversion system into a unified reconfigurable architecture. The same power conversion circuitry and controller that handle AC charging are also used for high-power DC charging, combining multiple functions into a single integrated system rather than requiring separate dedicated hardware for each charging mode
3Productivity
If DC-based EVSEs are used for charging, then the charging speed is fast, but the cost is high
Solution Approach 1:
The patent applies multi-functionality by enabling the vehicle's onboard charger to operate in two modes: traditional AC charging mode and high-power DC charging mode. The system can function as both an AC EVSE (receiving AC power from grid) and a DC EVSE (providing DC power to battery), eliminating the need for separate charging infrastructure and achieving fast charging using existing vehicle components
Solution Approach 2:
The patent applies self-service by utilizing the vehicle's existing onboard charger components to provide high-power DC charging functionality. Instead of requiring a complex external DC EVSE, the system uses the vehicle's own power conversion equipment, controlled by its existing charger controller, to perform high-power charging, thereby reducing external infrastructure complexity and cost
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
Enables rapid high-power charging using existing vehicle components, reducing the cost and complexity of external charging infrastructure.
Implementation Method 1
The inverter comprises a plurality of power switch devices... transform alternating current power to direct current power
Implementation Method 2
The motor comprises a stator which has a plurality of stator teeth and a plurality of stator windings
Implementation Method 3
A DC EVSE can transform alternating current power to direct current power
Data Source
Figure 1
Figure 2A
Figure 2B
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.