KR-20260064177-A - Design method for high-efficiency converter module for electric vehicle rapid charger and converter module manufactured thereby

Abstract

The present invention relates to a method for designing a high-efficiency converter module for an electric vehicle fast charger, comprising: a process of designing an AC/DC converter composed of a Power Factor Correction (PFC) converter that converts AC power into DC power and a DC/DC converter that boosts the converted DC power, wherein the signal pattern and power pattern inside the PCB are arranged as vertically as possible to prevent interference; a component placement process of confirming heat generation information of each component through thermal analysis of the AC/DC converter and arranging the components so that the heat distribution is uniform according to the confirmed heat generation information; an airflow analysis process of analyzing the airflow path during fan operation after arranging the components; and an enclosure design process of designing an enclosure by additionally providing a blower fan in a part where cooling efficiency is reduced according to the airflow; thereby optimizing charging efficiency and preventing malfunctions through optimal heat dissipation; and a high-efficiency converter module for an electric vehicle fast charger that improves the performance of the electric vehicle fast charger by preventing heat-induced damage and malfunctions through improved heat dissipation by providing a converter module designed thereby.

Inventors

• 조태석
• 이근택
• 김성진
• 김태원

Assignees

• 채비(주)

Dates

Publication Date

20260507

Application Date

20241031

Claims (4)

1. A converter design process for designing an AC/DC converter composed of a Power Factor Correction (PFC) converter that converts AC power to DC power and a DC/DC converter that boosts the converted DC power; A component placement process for confirming heat generation information of each component through thermal analysis of the above AC/DC converter, and arranging the components so that the heat distribution is uniform according to the confirmed heat generation information; An airflow analysis process for analyzing the airflow path during fan operation after arranging the above elements; An enclosure design process for designing an enclosure by additionally equipping a blower fan in the part where cooling efficiency is reduced due to the above airflow; A method for designing a high-efficiency converter module for an electric vehicle fast charger, characterized by being configured to include
2. A method for designing a high-efficiency converter module for an electric vehicle fast charger according to claim 1, characterized in that, during the winding process of a magnetic material in the converter design process, the signal pattern and power pattern inside the PCB are arranged as vertically as possible to prevent interference.
3. In claim 1, in order to improve the cooling efficiency of the part where the cooling efficiency is reduced during the above airflow analysis process, A method for designing a high-efficiency converter module for an electric vehicle fast charger, wherein the enclosure is designed by selecting one or more of the following: designing the enclosure by placing an additional blower fan around the element, installing a guide inside to allow air to remain around the element, or drilling a plurality of holes in the enclosure to allow air to pass through the element and be discharged.
4. In a high-efficiency converter module for an electric vehicle fast charger, wherein N AC/DC converters, each composed of a Power Factor Correction (PFC) converter that converts AC power into DC power and a DC/DC converter that boosts the converted DC power, are connected in parallel to each other, the AC/DC converter is disposed inside a housing. A high-efficiency converter module for an electric vehicle fast charger, characterized in that the side of the housing has a plurality of through holes, and a cover plate or a blower fan can be selectively installed in each through hole, so that a blower fan is further provided depending on the heat dissipation characteristics of the element.

Description

Design method for high-efficiency converter module for electric vehicle rapid charger and converter module manufactured thereby The present invention relates to a method for designing a high-efficiency converter module for an electric vehicle fast charger and a converter module manufactured thereby. More specifically, the invention relates to a method for designing a converter module to have an optimal heat dissipation effect, thereby preventing damage and malfunction caused by heat during the charging process and improving the performance of the electric vehicle fast charger, and a converter module manufactured thereby. Recently, as air pollution caused by the depletion and overuse of fossil fuels has emerged as a serious social issue, research and development on the use of renewable energy and eco-friendly transportation methods are actively underway. Among these eco-friendly modes of transportation, electric vehicles, in particular, are launching into the market by automakers worldwide in rapid succession because they produce no noise pollution during operation and do not emit air pollutants. In line with this trend, significant efforts are being made to develop and install electric vehicle charging systems to facilitate the widespread adoption and use of eco-friendly electric vehicles. The above electric vehicle charging device is classified into a slow charger and a fast charger according to the charging method. As shown in FIG. 1, the slow charger supplies AC power to the vehicle and converts it into DC power through an OBC (On Board Charger) inside the vehicle to charge the battery, and the fast charger converts AC power supplied from an external grid into DC power and supplies it to the vehicle to charge the battery. The means for converting AC power into DC is a converter module. Meanwhile, the capacity of slow chargers is steadily increasing to reduce the charging time of electric vehicles, and the converter modules currently used in most slow chargers are 10 to 20 kW class, while some 30 kW class is being developed for high voltage. These converter modules are configured such that a substrate, equipped with multiple components including a converter circuit, is placed inside a housing. Accordingly, the fast charger required for electric vehicles equipped with 800V batteries that are being released recently is at the 350kW level. When using existing 10-20kW converter modules, about 18 to 35 units are needed, and since they take up a lot of space due to the volume of the housing, the space occupied by the charger increases. However, when applying 30kW converter modules, only 12 units are needed, so there is an advantage in that the charger can be designed compactly. However, as mentioned above, when a 30kW converter module is applied, the charging speed increases in proportion to the increase in output power, but there is a problem of generating a lot of heat, which leads to a decrease in charging performance as well as safety accidents such as fire or short circuit. Figure 1 is a drawing showing the charging structure of a typical electric vehicle charger. FIG. 2 is a drawing showing a high-efficiency converter module for an electric vehicle fast charger according to the present invention. FIG. 3 is a drawing showing an example of a rectifier of a PFC converter according to the present invention. FIG. 4 is a drawing showing a toroidal core according to the present invention. FIG. 5 is a drawing showing a wire winding method of a converter according to the present invention. FIG. 6 is a drawing showing a magnetic material design structure according to the present invention. FIG. 7 is a drawing showing an AC/DC converter structure according to the present invention. FIGS. 8 and 9 are drawings illustrating examples of thermal analysis and airflow analysis of a converter module according to the present invention. FIG. 10 is a drawing showing an enclosure according to the present invention. It should be noted that in assigning reference numbers to the components of each drawing in this specification, identical components are given the same number as much as possible, even if they are shown in different drawings. Meanwhile, the meaning of the terms described in this specification should be understood as follows. Singular expressions should be understood to include plural expressions unless the context clearly defines otherwise, and terms such as "first," "second," etc. are intended to distinguish one component from another, and the scope of rights should not be limited by these terms. Terms such as "include" or "have" should be understood as not excluding in advance the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof. The term “at least one” should be understood to include all combinations that can be presented from one or more related items. For example, the meaning of “at least one of the first item, the second item and the third