Creating Compatibility between Level 3 DC Fast Chargers and Vehicle Batteries with an On-board Conversion Module
2022-01-0191
03/29/2022
- Content
- Incompatibility between existing Level 3 charging infrastructure and emerging xEV vehicles is a major source of range anxiety today, and solving this problem is essential if OEMs are to continue their drive to electrify vehicles. Consumers need to be confident that the charger they find will charge their vehicle. Onboard conversion solutions offer a more holistic approach than building out charging infrastructure to enable 400V or 800V compatibility. An onboard approach can be adopted much more quickly and with no capital investment in charging infrastructure. The incompatibility between 800V batteries and 400V chargers can be solved through “battery virtualization.” With battery virtualization, the charger “sees” a 400V battery on one side of the onboard charger even while the 800V battery is connected to the other side. This approach starts from the battery voltage and adapts it to the voltage range acceptable by charging station. This paper will address how we virtualize a battery using a bi-directional DC/DC converter serving a dual purpose, supporting: a. fast-charging compatibility b. the powertrain to improve range for low RPM driving We will introduce the “virtual battery”, which is the result of high performance power conversion. With technical description for Sine Amplitude Converter (SAC), we will provide explanation how virtual battery makes main battery compatible with any DC fast charging station and how we can improve range for low RPM driving. For proposed system architecture, we will show how high efficiency power conversion of 99%, at high power rates 50+ kW, simplifies and miniaturizes thermal management additionally improving driving range and offer flexibility.
- Citation
- Muhedinovic, H., "Creating Compatibility between Level 3 DC Fast Chargers and Vehicle Batteries with an On-board Conversion Module," SAE Technical Paper 2022-01-0191, 2022, .