Description:TECHNICAL FIELD
[1] The present disclosure relates, in general, to control of operation of integral, Hi-Power IP EV Charger with Flyback Regenerating Snubber for Fire safe Battery-HIPEC. In particular. In particular, the present disclosure relates to a means to operate a EV Charger execute all required essential functions as, IP, Power enhancements in flyback and Battery Fire Safety.
BACKGROUND
[2] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[3] Most of the EV charger are based non-flyback complex topology leads to complex manufacturing process and need most skilled resources as Flyback topology fails to deliver power and efficiency requirement although this topology is flexible massive usage and most suitable control of operation of Battery charging. Our invention successfully eliminates these drawbacks and offers a novel solution for EV Charger by eliminating all drawbacks of flyback topologies by implementing regenerating snubber and schemes of transformer energy couplings, enhanced efficiency that allows to meet IP requirements and faster control loop response enables battery fire safety.
[4] Most common method of EV Charger are adapted LLC/LCC topology that works on resonance properties of passive components which leads to complex scheme, control and having limited production and testing flexibility, need skilled resource and best infrastructure. This topology needs to maintain thermal rises of component as these impacts on resonance process of passive component, hence to ensure thermal force or active collings scheme are became compulsion. In case of force colling Ingress protection are very challenging. This product comes under outdoor category and non-IP impact reliability. Here slower loop/control response impacts on battery fire safety
[5] It is thus imperative to eliminates all above existing issues/limitations for EV charger to optimize EV Charger for fire safe battery in our existing infrastructure with commonly available resource.
OBJECTS OF THE DISCLOSURE
[6] A general object of the present disclosure is to provide a system which enable to use virtue of flyback topology and eliminates its limitations for EV charging.
[7] Another object of the present disclosure is to provide a system that can operate reliably across a wide range of voltages.
[8] Another object of the present disclosure is to provide a system that has a long operating life.
[9] Another object of the present disclosure is to provide a system that is very economical to implement.
SUMMARY
[10] The present disclosure relates, in general, to control of operation of battery charging. In particular, the present disclosure relates to a means to implement enhanced powered flyback topology enable to meet IP and fire safety.
[11] In an aspect, the present disclosure provides a system to reduce size of battery charger. FIG. 1 illustrates a representation of a first means to battery charging the system is LLC topology 100 includes:102 Input Filter, 103 Buck-Boost AC-DC Cell,104 LLC DC-DC Resonant Cell. This architectures are commonly used for battery charging along with charging control circuit
[12] In an embodiment, the system includes FIG. 4 illustrates a representation 400 of invented battery charging: - A first 402 Input Filter 403 High Voltage Rectification and filtering, 404 High Speed Switching and
[13] Control, 405 Regenerative Snubber, this section is our critical part of invention and this enables to enhance power delivery of flyback topology, Csn, Dsn1 and Rsn1 are refilling Cdc1 for positive transient and alternatingly for negative transient Csn, Dsn2, Rsn2 will refill Cdc1 capacitor and as well as protect N Chanel Mosfet. 406 Coupled Inductor, This another critical part of our invention,
[14] In this identical Inductor L placed as per diagram to meet coupling factor to very close to 1. 407 High Speed Rectification and charging control. In this section Charging current doubled by this scheme and will ensure and control current rate.
[15] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF DRAWINGS
[16] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a
parts of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the present disclosure.
[17] FIG. 1 illustrates a representation of a conventional means to charge the battery.
[18] DETAILED DESCRIPTIONS
[19] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[20] In general, for Energy storage batteries are commonly used and in order to enhance power density industry progressed towards lithium from lead acid. As this progress upgraded existing charger from linear (low frequency 50Hz) towards high frequency LLC based topology. As this sudden change from low frequency to high frequency complex topology created vacuum/ bottle neck in the industries. As explained fig 1 there are multiple switching and control loops creates challenges in development and production cycle result poor production yields with huge cost penalty.
[21] Hence there are need of target power-density in battery charger, that can be achieved by migrating low frequency 50Hz to high frequency basic or simple topologies i.e., FLYBACK topology. As industry already learned and proved the same in LED lighting.
[22] Fig 2 shows basic blocks of flyback topology, it has three prominent block that completes power conversion Input Processing, High frequency switching and control and output processing. In flyback topology primary side switch and secondary rectifier conduct alternatively that allows faster system control loop which will meet battery fire safety while charging. This topology has less component having best MTBF/ ITBF.
[23] FIG. 3 illustrates a representation of a first means to battery charging. These schemes are appropriate for wattages up to 150Watt. There are snubber and transformer leakage are the main obstacle/bottle neck. There are several improvement steps taken to reduce Snubber and Transformer losses.
[24] Our invention is continued to the same direction. Power semiconductors are the heart of power electronics equipment. Snubbers are circuits which are placed across semiconductor devices for protection and to improve performance, reduce or eliminate voltage and current spikes, limit dI/dt or dV/dt. transfer power dissipation from switch to snubber Resistor and Capacitor.
[25] Hence for higher wattage we need to use bigger capacitor and high wattage resistor that restricts the limit of power delivery of flyback topology.
[26] There is another bottle neck in flyback where power is not able retrieve what feed to input side of transformer due to turn and thickness of primary and secondary winding. These coupling losses increases thermal dissipation inside the transformer which raise winding temperature and insulation break downs take places.
[27] To overcome snubber and transformer losses possible combination are explored and we have arrived on our invention were regenerative schemes are implemented to regain snubber losses back to high voltage dc capacitor Cdc1
[28] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE DISCLOSURE
[29] The present disclosure provides Hi-Power IP EV Charger with Flyback Regenerating Snubber for Fire safe Battery-HIPEC charging systems with less components with higher power density.
[30] The present disclosure provides a system that can operate reliably across a wide ranges of grid utility input voltages.
[31] The present disclosure provides a system that has a long operating life.
[32] The present disclosure provides a system that is economical to implementation.
[33] The present disclosure provides a system that is Ingress protected and sustain environmental challenges
[34] The present disclosure provides a system that is extended power range for flyback topology.
[35] The present disclosure provides a system that is meet highest energy efficiency rating
[36] The present disclosure provides a system that is ensuring battery fire safety while charging the battery.
[37] The present disclosure provides a system that is lowest commercial cost/ per watt.
[38] The present disclosure provides a highest production yield in conventional manufacturing infrastructure.
, Claims:I Claim:

1. A system to Hi-Power IP EV Charger with Flyback Regenerating Snubber for Fire safe Battery-HIPEC higher power density and meets functional requirement of title, the system (400) comprising:
an input (401) configured to receive an input current;
an output (408) coupled to a load comprising one or more battery, the output (408) configured to supply an output current to the all type of battery or equivalent load;
A first 401AC input, 402is input filter class capacitor (Cf) connected in series with line filter/ common mode choke Lf, 403 is high voltage rectification and filtering consist of general-purpose bridge rectifier D1 and DC Bulk capacitor Cdc1, 404 is High Speed Switching and control consists of Flyback Resonant Controller, N-channel Mosfet, voltage and current sensors.
405 is regenerative snubber consists of Csn, Dsn1 and RSn1 are connected together in series in between junction of Drain of MOSFET N and coupled inductor to DC Bulck Capacitor Cdc1. Again Csn, Dsn2 Rsn2 are connected together in series in between junction of Drain of MOSFET N and coupled inductor and Source of MOSFET N;
406 is coupled inductor where four identical inductor L are connected together. In first left side they are connected in series where as other side there parallel via Drect1 and Drect2.
407 is High Speed rectification and Charging Control consist of high speed Rectifier Drect1 and Drect2 concerted together in junction with Output
Filter capacitor Cdc2.
408 is output section here load Battery will be connected.