In-Vehicle Charger Circuit for Wide-Range Battery and AC Power
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Solution Overview
Problem
Existing in-vehicle chargers face challenges in achieving high-voltage battery charging and AC power supply functions, particularly for 400 V batteries and hybrid electric vehicles, due to limited input/output voltage ranges, making it difficult to efficiently charge and power devices across various voltage requirements.
Innovation Solution
The in-vehicle charger incorporates a bidirectional AC/DC converter, a resonant isolated DC/DC converter, and a voltage adjustment DC/DC converter, along with a control device, to expand the input/output voltage range by using a transformer unit, switching legs, and a resonance circuit, enabling efficient charging, AC power supply, and intermediate voltage supply functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single charging circuit configuration is used, then the circuit structure is simple, but the input/output voltage range is limited and cannot support both 400V high-voltage battery charging and 200V AC power supply functions
Solution Approach 1:
The charging circuit is divided into multiple independent DC/DC converter modules, each capable of operating at different voltage levels. This segmentation allows the system to support multiple voltage ranges (400V, 200V, and intermediate voltages) by activating appropriate modules, thereby expanding the overall voltage adaptability without requiring a complete redesign for each voltage level.
Solution Approach 2:
The charging circuit is designed with multi-functional DC/DC converters that can operate in different modes to achieve various functions. The same hardware infrastructure supports high-voltage battery charging, AC power supply, and intermediate voltage device charging simultaneously, making the system universal across different voltage requirements and application scenarios.
2Adaptability or versatility
If the charging circuit is designed for 400V high-voltage battery charging, then high-voltage charging function is achieved, but it becomes difficult to perform AC power supply function at 200V output
Solution Approach 1:
The charging circuit incorporates dynamically adjustable DC/DC converters that can change their operating voltage levels based on real-time requirements. The control device dynamically switches between different conversion ratios and operating modes, enabling seamless transition between 400V charging mode, 200V AC power supply mode, and intermediate voltage mode without manual intervention or complex reconfiguration.
3Adaptability or versatility
If intermediate voltage devices are to be supported, then voltage adaptability is improved, but the circuit configuration becomes more complex
Solution Approach 1:
The charging circuit employs a nested hierarchical structure where DC/DC converters for different voltage levels are integrated within a unified circuit framework. The intermediate voltage conversion capabilities are nested within the existing high-voltage conversion architecture, allowing intermediate voltage devices to be supported by activating specific nested modules without adding entirely separate external circuits, thus managing complexity through structured integration.
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 configuration allows for efficient voltage conversion and expanded voltage range capabilities, enabling the charger to effectively charge high-voltage batteries, supply power to AC loads, and operate auxiliary devices across a range of voltages, including those used in both battery electric and hybrid electric vehicles.
Implementation Method 1
a transformer unit configured to perform voltage conversion according to a winding ratio
Implementation Method 2
a resonance circuit provided between the transformer unit and the second switching leg. The first switching leg and the second switching leg operate at a drive frequency equal to a resonance frequency of the resonance circuit
Data Source
AI summary
There is provided an in-vehicle charger including a bidirectional AC/DC converter to which an AC power supply or an AC load is connected; a resonant isolated DC/DC converter to which the bidirectional AC/DC converter is connected; a voltage adjustment DC/DC converter to which the resonant isolated DC/DC converter is connected and to which a high-voltage battery is connected; and an intermediate voltage junction circuit that supplies DC power from between the resonant isolated DC/DC converter and the voltage adjustment DC/DC converter to an intermediate voltage load that operates at an intermediate voltage lower than a voltage of the high-voltage battery.