Universal Charger Circuit for AC DC Input Integration
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Solution Overview
Problem
Current electric vehicle charging systems require separate high-voltage boosters for DC charging and on-board chargers for AC charging, leading to redundant infrastructure and inefficiencies.
Innovation Solution
A single charger circuit that combines the functions of high-voltage boosters and on-board chargers, utilizing AC and DC inputs, with a selector switch, boost converter, and optional buck-boost converter to generate the necessary voltage for high-voltage batteries, and includes electrical isolation options for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate high-voltage boosters and on-board chargers are provided for DC and AC charging respectively, then the charging function is reliable and covers both charging types, but the device complexity increases and infrastructure redundancy occurs
Solution Approach 1:
The patent combines the functions of separate high-voltage booster and on-board charger into a single integrated charger unit. The unified charger includes a rectifier for AC input, a DC input terminal, a converter with coupled inductors, and a controller that manages both AC and DC charging paths, thereby reducing infrastructure redundancy while maintaining reliable charging capability for both AC and DC modes
Solution Approach 2:
The integrated charger is designed to perform multiple functions: it can accept both AC and DC input currents, convert them to the required high voltage for battery charging, and provide both high-voltage output and low-voltage output. The converter circuit with coupled inductors and the controller enable the same hardware to handle different charging types universally
2Device complexity
If a single integrated charger handles both AC and DC inputs, then device complexity is reduced and infrastructure redundancy is eliminated, but the adaptability to handle different input voltages and charging modes increases
Solution Approach 1:
The charger employs dynamic control through a controller that monitors input type (AC or DC) and automatically adjusts the operating mode of the converter circuit. The selector switch and control logic dynamically reconfigure the circuit parameters to optimize performance for the specific charging mode being used, enabling the system to adapt to different input conditions without manual intervention
Solution Approach 2:
The converter circuit parameters (such as inductor coupling, switching frequency, and voltage conversion ratio) are dynamically adjusted based on the input type. The controller modifies these parameters to efficiently handle both AC rectified output and direct DC input, as well as to provide appropriate high-voltage and low-voltage outputs based on battery charging requirements
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 from a wide range of input voltages, reducing the need for separate units and enhancing charging efficiency by adapting to different power sources and voltage requirements.
Implementation Method 1
an input filter and a rectifier are connected downstream of the AC connection
Implementation Method 2
a boost converter is provided which generates the necessary voltage, e.g. 800 V, for the high-voltage battery
Implementation Method 3
instead of the boost converter a buck-boost converter is used
Implementation Method 4
the electrical isolation can be brought about e.g. by means of a transformer with an AC section
Data Source
AI summary
A charger for a motor vehicle and to a method for charging an energy store of the motor vehicle.