Integrated xEV Power Conversion for Charger and Traction Consolidation
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Solution Overview
Problem
Current electric vehicle power conversion systems require multiple devices and converters, leading to increased volume, cost, and limited power capacity due to the need for separate chargers and controllers for high and low voltage batteries, as well as traction converters.
Innovation Solution
An integrated power conversion apparatus that combines an on-board charger, low voltage DC/DC converter, and traction converter into a single system with multiple converter units and a power conversion control unit, capable of operating in various modes to charge and supply power between high and low voltage batteries and an external device or motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power conversion apparatuses are used for on-board charger, low voltage DC/DC converter, and traction converter, then each function can be independently controlled, but the overall system volume increases and cost increases
Solution Approach 1:
The patent combines the on-board charger, low voltage DC/DC converter, and traction converter into a single integrated power conversion apparatus. This merging of previously separate devices reduces the overall system volume while maintaining the functional capabilities of each component through shared hardware resources and unified control architecture.
Solution Approach 2:
The integrated power conversion apparatus is designed to perform multiple functions simultaneously - charging the high voltage battery, converting voltage between high and low voltage batteries, and driving the traction motor. This multi-functional design eliminates the need for separate dedicated devices for each function, thereby reducing system volume and component count.
2Reliability
If separate power conversion apparatuses are used for on-board charger, low voltage DC/DC converter, and traction converter, then each function can be independently controlled, but the device complexity increases
Solution Approach 1:
The patent merges three separate power conversion devices into one integrated apparatus, reducing the total number of devices from three to one. This consolidation maintains independent control capability through a unified controller that manages all functions, thereby reducing device complexity while preserving functional independence.
Solution Approach 2:
The integrated apparatus serves as a universal power conversion system that can perform charging, voltage conversion, and motor driving functions. This multi-functionality reduces the number of required devices while maintaining the ability to independently control each function through software-based control strategies.
3Power
If separate power conversion apparatuses are used, then power capacity can be individually optimized, but the overall cost increases
Solution Approach 1:
The patent combines three separate power conversion systems into one integrated apparatus, reducing the total component count and manufacturing complexity. This merging allows for shared manufacturing processes, reduced assembly requirements, and lower overall production costs while maintaining the power capacity needed for each function.
Solution Approach 2:
The integrated power conversion apparatus provides a universal platform that can deliver the required power capacity for charging, voltage conversion, and motor driving through a single system. This approach reduces the total cost of ownership by eliminating redundant components and reducing the number of controllers needed, while still providing individually optimized power delivery for each function.
Data Source
AI summary
According to the integrated power conversion apparatus and method according to the exemplary embodiment of the present disclosure, the on-board battery charger (OBC), the lower voltage battery charger (LDC), and the traction converter (TC) are integrated to convert the power so that all the functions which need to be performed by the power conversion system of the related art can be performed. Further, the number of switches is reduced to increase a power density and not only the number of switches, but also the number of controllers is reduced to improve feasibility.