Vehicle Charging Device Overcurrent Control via Power Factor Correction
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Solution Overview
Problem
Vehicle charging devices for hybrid vehicles often experience overcurrent issues due to external AC voltage instability, leading to frequent shutdowns and inconvenience for users, as existing control methods fail to differentiate between AC voltage-related overcurrents and hardware failures effectively.
Innovation Solution
A method and system that utilize a controller to sense overcurrent in the power factor correction circuit, adjust output voltage and power levels based on predetermined reference values, and determine the cause of overcurrent to minimize interruptions by turning off or on the power factor correction circuit accordingly, thereby preventing unnecessary shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vehicle charging device stops operation unconditionally when overcurrent is generated, then device stability is maintained, but charging efficiency and user convenience deteriorate due to frequent interruptions
Solution Approach 1:
The controller changes the output voltage parameter of the power factor correction circuit dynamically. When overcurrent is detected, the controller increases the output voltage to counteract the overcurrent condition, rather than simply shutting down the device. This parameter adjustment allows the device to maintain operation while resolving the overcurrent issue.
Solution Approach 2:
The system transitions from a static on/off control mode to a dynamic control mode where the output voltage is continuously adjusted based on overcurrent detection. The controller monitors overcurrent conditions and dynamically modifies the power factor correction circuit's output voltage, enabling the system to adapt to changing electrical conditions and maintain stable operation.
2Reliability
If the power factor correction circuit output voltage is increased to resolve overcurrent, then overcurrent issues are solved, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The controller implements a feedback mechanism by monitoring overcurrent conditions in real-time and using this information to adjust the output voltage of the power factor correction circuit. The system continuously detects overcurrent and responds by increasing output voltage, creating a closed-loop control system that automatically resolves overcurrent issues without complex external intervention.
Solution Approach 2:
The existing power factor correction circuit is made multi-functional by enabling it to both correct power factor and dynamically adjust output voltage to resolve overcurrent conditions. This universal approach allows a single component to handle multiple functions, reducing the need for additional dedicated overcurrent protection circuits.
3Reliability
If the controller increases output voltage by multiplying overcurrent generations by voltage command transformation constant, then overcurrent is corrected, but manufacturing precision requirements increase
Solution Approach 1:
The system uses the overcurrent generation count itself as part of the control parameter. The controller multiplies the number of overcurrent generations by a voltage command transformation constant to determine the voltage increase amount, allowing the system to self-regulate based on its own operational history without requiring external precision calibration.
Data Source
AI summary
A method and system of controlling a charging device for vehicles are provided. The method includes sensing overcurrent in a power factor correction circuit of the charging device and turning off the power factor correction circuit upon sensing overcurrent. An output voltage of the power factor correction circuit is then increased when the number of generations of sensed overcurrent is equal to or less than a predetermined first reference value and the power factor correction circuit is turned on.