Vehicle Solar Charging With Multi-Winding DPP Power Balancing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing solar charging systems for vehicles face issues with power generation imbalance among multiple PV modules due to shading, pollution, or aging, leading to reduced output and productivity, and require numerous transformers and controllers for compensation, which are bulky and costly.

Innovation Solution

A solar charging system using a differential power processing (DPP) transformer with a multi-winding structure and integrated magnetic body, along with a single secondary side switch, to compensate for power generation imbalances among PV modules, reducing the number of required elements and controllers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple PV modules are connected in series to increase power output, then the total power generation capacity is improved, but the output current is limited by the PV module with minimum output, causing power imbalance and system inefficiency

Engineering Contradiction:

Improvetotal power generation capacityVSAvoidsystem efficiency

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The patent divides the solar charging system into multiple independent power processing channels, each handling a specific PV module. The DPP transformer separates the power flow paths, allowing each module to operate independently at its optimal current level rather than being constrained by the weakest module in a series connection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The DPP transformer acts as an intermediary device that mediates between PV modules with different output characteristics. It transfers excess power from high-output modules to compensate for low-output modules, balancing the power distribution without requiring all modules to operate at the same current level.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conventional transformers are used for each PV module to compensate for power imbalance, then power balance is improved, but the device complexity and number of components increase

Engineering Contradiction:

Improvepower balanceVSAvoidnumber of transformers and controllers

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple transformer functions into a single DPP transformer with multi-winding structure. This integrated transformer handles power conversion for multiple PV modules simultaneously, eliminating the need for separate transformers and controllers for each module while maintaining power balance compensation capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The DPP transformer is designed with multi-functionality to serve multiple PV modules through its multi-winding structure. A single controller manages the entire system, and the transformer performs both power conversion and power balance compensation functions across all connected modules, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple transformers and controllers are used for each PV module, then individual module control is improved, but the system size and component count increase

Engineering Contradiction:

Improveindividual module controlVSAvoidsystem size

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The patent combines multiple control functions into a single controller that manages the entire solar charging system. The controller communicates with all PV modules and coordinates the DPP transformer operations, eliminating the need for separate controllers for each module while maintaining individual module adaptability through centralized control.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The DPP transformer uses a nested multi-winding structure where multiple windings are integrated within a single transformer core. This nested design allows the transformer to handle multiple PV modules' power flows simultaneously within a compact structure, reducing the overall system volume while maintaining individual module control capabilities.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 system effectively compensates for power generation imbalances with a simplified, high-density design using fewer components, achieving miniaturization and cost-effectiveness by minimizing the number of transformers and controllers.

Implementation Method 1

a solar panel that converts solar energy into electrical energy

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

a differential power processing (DPP) transformer that converts power generated from the first PV module and the second PV module by using a magnetic body having a multi-winding structure

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12600254B2Solar charging system for vehicle

Publication Date: 2026.04.14 HYUNDAI MOTOR CO LTD

AI summary

A solar charging system for the vehicle includes a first photovoltaic (PV) module, a second PV module serially connected to the first PV module, and a differential power processing (DPP) transformer that converts power generated from the first PV module and the second PV module by using a magnetic body having a multi-winding structure.