Transformer Winding Topology for Dual Battery Charging
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Solution Overview
Problem
Conventional battery charging apparatuses consume the auxiliary battery during high voltage battery charging, leading to inefficient voltage management and a shortened lifespan of the high voltage battery due to frequent charging and discharging cycles.
Innovation Solution
A battery charging apparatus with a hybrid power converting unit using a common transformer to generate separate voltages for charging both high voltage and auxiliary batteries, along with a switching unit to selectively input AC power or high voltage battery voltage for charging, eliminating the need for a separate low voltage DC converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate low voltage DC converter is used to charge the auxiliary battery, then the auxiliary battery can be charged independently, but the device complexity and cost increase
Solution Approach 1:
The transformer is designed with multiple secondary windings that can serve different functions: one winding charges the high voltage battery while another winding simultaneously charges the auxiliary battery. This multi-functional design eliminates the need for separate charging devices, reducing system complexity while maintaining reliable charging capability for both batteries
Solution Approach 2:
The patent combines the auxiliary battery charging function with the existing high voltage battery charging system by integrating it into the same transformer. The multiple secondary windings are connected to different batteries, merging two charging functions into a single integrated apparatus, thereby reducing device complexity and cost
2Productivity
If the auxiliary battery is consumed during high voltage battery charging, then the high voltage battery charging can proceed uninterrupted, but the auxiliary battery voltage decreases requiring additional charging operations
Solution Approach 1:
The patent enables continuous charging of both batteries simultaneously through the transformer's multiple secondary windings. While the high voltage battery is being charged from AC power, the auxiliary battery is also charged from the same AC power source through a different winding, ensuring continuous useful action for both batteries without interruption or voltage depletion
Solution Approach 2:
The auxiliary battery is charged in advance during the high voltage battery charging process itself, rather than waiting for the high voltage battery to finish charging. This preliminary action ensures the auxiliary battery maintains adequate voltage levels throughout the charging process, preventing the need for additional recharging operations
3Productivity
If a separate low voltage DC converter is added to charge the auxiliary battery, then the auxiliary battery can be charged simultaneously, but the manufacturing cost and device complexity increase
Solution Approach 1:
The transformer is designed with multiple secondary windings that provide different voltage levels for charging different batteries. This universal design allows a single device to charge both high voltage and auxiliary batteries simultaneously, eliminating the need for separate charging apparatus and reducing manufacturing complexity and cost
Solution Approach 2:
The transformer's secondary side is segmented into multiple independent windings, each capable of providing power to different batteries. This segmentation allows the system to charge multiple batteries simultaneously through a single integrated device, achieving dual battery charging capability without requiring separate charging circuits or converters
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 simultaneous charging of both batteries with improved efficiency, reducing charging time and extending the lifespan of the high voltage battery by optimizing power conversion and eliminating the need for a separate low voltage DC converter.
Implementation Method 1
a hybrid power converting unit configured to use a common transformer to separately convert AC power into a first voltage and a second voltage
Data Source
AI summary
A battery charging apparatus includes a converting unit, first and second charging units and a switching unit. The converting unit separately convert AC power into a first voltage and a second voltage. The first charging unit drops the converted first voltage and charge a high voltage battery with the dropped first voltage. The second charging unit drops the converted second voltage or a third voltage of the high voltage battery, and charges an auxiliary battery with the dropped second or third voltage. The switching unit performs, in a first mode, the charging of the high voltage battery and the auxiliary battery by the AC power, and in a second mode, stops the charging of the high voltage battery by the AC power and performs the charging of the auxiliary battery by the third voltage.