Optimized power and management system with advanced voltage control for vehicle devices at 48v

Abstract

The invention is an advanced power and management system for vehicle devices at 48V, and in particular for electric turbochargers (eBoosters). It integrates a power supply unit with IGBT technology, managed by a dedicated PLC with customized software, to provide an optimized flow of current. The system uses an isolation transformer and specific filters to minimize voltage peaks, ensuring a cosϕ of 0.98 and extremely low output ripple. The invention allows precision control of voltage and current, improving the performance of the electric turbocharger, mitigating voltage peaks and increasing the efficiency of the entire system.

Description

[0001] Optimized power and management system with advanced voltage control for vehicle devices at 48V

[0002] Description

[0003] Field of the invention

[0004] The present invention falls within the field of automotive technology, and more specifically relates to an advanced power system for vehicle devices at 48V to be used during technical tests and quality checks of hot engines.

[0005] Prior art

[0006] In the field of automotive engineering and, in particular, in hybrid engine technology, significant innovations have been seen in recent years aimed at improving energy efficiency, reducing emissions and increasing overall vehicle performance. These advances, which mainly concern the electrification of components, have led to the need to develop new power systems for the various devices at 48V used in such engines in parallel. In such a context, a fundamental element is represented by electric turbochargers, or "eBoosters", which contribute to improving the efficiency of internal combustion engines. Electric turbochargers operate powered by high amperage direct current, rather than exploiting the thrust of exhaust gases as in traditional turbochargers, and are particularly useful in increasing the driving torque, regardless of the number of revolutions, especially at low speeds, thus eliminating the effect known as “turbolag”. The use of such devices in mild hybrid cars represents one of the most significant innovations in the automotive field.

[0007] However, several problems and technical limitations have emerged regarding the power supply of such devices in the engine testing phases. In operational mode, i.e., on the road, these devices are powered by the car battery, but during the technical test this solution is not feasible.

[0008] In fact, the turbocharger is powered with a high amperage direct electrical voltage and has the characteristic of requiring large quantities of current almost instantaneously, depending on the power demand applied to the engine, and this poses problems with regards to requested current peaks.

[0009] In the state of the art, there is no consistent way to solve the problem of powering the electric turbochargers of the engines under test. There are Research and Development power supply units on the market but they do not have the characteristics suitable for "Heavy Duty" use. Many manufacturers resort to artisan solutions by exploiting components available on the market but not specifically designed for this purpose, such as modified automotive batteries or power supply units with capacitors. Although functional, these solutions have various critical issues, including reliability problems, sudden depletion of the charge during testing, maintenance and disposal. Furthermore, the use of these artisan solutions, although common, has proven to be poorly suited to operating needs: in addition to issues of charging maintenance and management, the batteries also have environmental impact problems, which is incompatible with the objective of developing more sustainable transport technologies.

[0010] At the same time, it is essential that the power system, especially for electric turbochargers, but in general for all vehicle devices at 48 V, is capable of interacting digitally with the control desk, which collects and analyzes all the parameters in real time. In fact, this function allows to compare the actual engine performance with the expected performance, providing crucial data for system optimization. Furthermore, the mass production of the automotive market, and therefore the quality checks at the end of the line, requires reliable systems which do not have critical issues such as sudden depletion of the charge or energy efficiency, as the test must be carried out for a prolonged period of time and it is very easy to bum the electric turbocharger if it is not supplied with the voltage and amperage required by the technical specifications. Therefore, in the current state of the art, there is an unmet need for a power system dedicated to all vehicle devices at 48V, including electric turbochargers, such as "eBoosters", which is reliable, efficient, environmentally friendly and can be integrated with test data acquisition systems. This solution, the creation of which is evidently motivated by the need to primarily power turbochargers but which can be extended to any equivalent vehicular device with a voltage of 48V, should overcome the limitations of what is currently available during hot engine tests. Furthermore, such a system should facilitate the diagnosis and management of problems, preventing connection errors and ensuring operator safety.

[0011] Based on these considerations, the need to develop a new approach which should be capable of overcoming the technical and operational problems of the solutions currently in use appears clear, ensuring more reliable performance and easier integration with data acquisition systems. The object of the present industrial patent application is therefore to introduce a new and alternative solution through the proposal of a highly innovative power system for vehicle devices at 48V, and in particular for electric turbochargers, which combines efficiency, reliability and environmental sustainability, optimally integrating hot engine testing procedures. The device, designed to be safe for operators, prevent connection errors and manage problem diagnosis, is managed by a dedicated local PLC with customized software, can take voltage and current readings which can be displayed on the control bench, and allows the verification of Volt / Amp value correctors during the operation of a cycle.

[0012] Description of the invention

[0013] With the present patent application for an industrial invention, it is intended to describe and claim a device provided with at least a new and alternative solution to the solutions known so far and / or to satisfy one or more needs perceived in the art and in particular deduced from what has been reported above. To accomplish this purpose, the inventors developed a highly optimized power and management system with advanced voltage control, specifically designed to power vehicle device at 48V during internal combustion engine testing, with a particular focus on the power supply of the electric turbocharger (eBooster). The system consists of a 400 / 45V isolation transformer which converts electrical energy from a high voltage of 400V to a lower and more manageable voltage of 45V. This transformer also allows the negative pole of the motor to be grounded, acting as an isolation transformer.

[0014] At the heart of the system is a power supply unit with IGBT (Insulated Gate Bipolar Transistor) technology, which uses four IGBTs protected by RC filters optimized to safeguard them from voltage gradients. The power supply unit has been designed to power devices with a voltage of 48V within the minimum tolerance envisaged by the technical specifications, and is capable of providing a current up to 150A almost instantaneously. As mentioned, a distinctive characteristic of the system is the accurate voltage control. The power supply unit uses an H- bridge to maintain a cos4> of 0.98, ensuring a low voltage ripple and stable supply of 48V. During the engine startup simulation, the voltage gradually rises up to the desired level in approximately 8 seconds and remains constant until the simulated shutdown phase. For further stability and prevention of voltage peaks, the system integrates Zehner filters and inductors in the power supply circuit. These filters, together with the line reactor which provides further dv / dt filtering, are particularly effective at mitigating voltage peaks, especially during the acceleration phases when the eBooster receives impulse current requests.

[0015] The management and monitoring of the system are entrusted to a dedicated Programmable Logic Controller (PLC). This PLC is programmed with custom software to meet the specific needs of test applications and controls the power supply, monitoring various parameters, such as voltage and current, during the operating phases. In addition, the system is provided with a CAN-Bus card which collects voltage and current data to display on the car's control unit. These readings can also be displayed on the QE 48V through transducers which provide a 0- 5 V analog output to the control desk, with acquisitions every 250ms.

[0016] Through a careful series of tests and analyses, the system has been optimized to limit the onset of voltage peaks and ensure a stable and reliable power supply. Hardware and software modifications, including adapting ramp times, settling, holding, and cycle measurement during the idle-to-load transition, and the implementation of Zehner filters and inductors, helped create a power system for vehicle devices, and in particular for the highly effective and high- performance eBooster.

[0017] In an embodiment of the invention, the Programmable Logic Controller (PLC) software is provided with a modular architecture which allows specific control algorithms to be loaded or modified for different types of vehicle device at 48V or for future versions of the eBooster. The software can be updated by means of a user interface based on a touch-screen control panel with Ethernet connection, which allows operators to configure parameters such as voltage and current limits, or load new control profiles through a library of preset algorithms. In another embodiment of the invention, a mixed-flow cooling system is integrated which uses finned aluminum heat sinks, variable speed fans and a liquid cooling system with a radiator and pumps. The cooling system is designed to maintain the temperature of the IGBTs and other components within a range from 25 °C to 40°C. The PLC monitors temperature through thermocouple sensors and automatically adjusts fan speed and coolant flow to optimize thermal efficiency.

[0018] In a subsequent embodiment of the invention, the said transformer is optimized using a silicon iron alloy core with high permeability. The transformer design comprises low-resistance windings with high-purity copper cables and a shielding system to reduce magnetic leakage. This results in an operational efficiency of more than 97%.

[0019] Finally, in a further embodiment of the invention, advanced protection mechanisms are integrated which include circuit breakers with a response time of less than 5 milliseconds and varistors with an energy absorption capacity of at least 40J. These devices are monitored by the PLC, which can react to overcurrent or overvoltage events by isolating sections of the circuit or adjusting operating parameters to prevent any damage to the system.

[0020] The advantages offered by the present invention are evident in the light of the description presented thus far and will be even clearer thanks to the attached figures and the related detailed description.

[0021] Description of the figures

[0022] The previous advantages, as well as other advantages and characteristics of the present invention, will be illustrated by referring to the attached figure, which is to be considered purely illustrative and not limiting or binding for the purposes of the present patent application, in which:

[0023] - FIGURE 1 shows the operating diagram of the system in question, in which the transformer 10, the IGBT power supply 20, the Zehner filters and inductors 30, the vehicle device 40, the car control unit 50 and the PLC 100 are visible. Detailed description of the invention

[0024] It will be immediately obvious that countless variations and modifications can be made to what has been described (for example relating to shape, dimensions, arrangements and parts with equivalent functionality) without departing from the scope of protection of the invention as appears in the attached claims.

[0025] The present invention will now be illustrated, by way of non-limiting or binding example in relation to the present inventive concept, as an optimized power and management system with advanced voltage control for vehicle devices at 48V. The system, as shown in the operational diagram shown in Figure 1, starts with a transformer 10. This transformer, which acts as an isolation transformer by allowing the negative pole of the motor to be grounded, converts the electric energy from a high voltage of 400V to a lower, more manageable voltage of 45V. From here, the low voltage energy is routed to the IGBT power supply 20. This, comprising at least 4 IGBTs protected with RC (Resistor-Capacitor) filters optimally calculated to protect against voltage gradients, uses an H-bridge to regulate the supply voltage and current, and is designed to maintain a high factor of power (cos4> greater than 0.98) during operation. Here the voltage and current of the electrical power supply which powers the entire system are regulated, reducing the dv / dt output and thus eliminating potential risks of electromagnetic disturbances. The power supply 20, in addition to constantly monitoring the input and output voltage to ensure the stability of the power supply, implements a feedback circuit for the realtime control of the supply voltage. The system branches into three distinct paths from the power supply 20. The first path is a bidirectional connection with a PLC 100. This PLC 100 monitors and manages the operation of the power supply 20, ensuring that the electrical power supply is distributed correctly and efficiently. The second path directs the electric energy to the Zehner filters and inductors 30. These filters 30, designed to deal with voltage peaks above 60V, eliminate any disturbances and fluctuations in the electrical power supply, thus protecting the vehicle devices at 48V 40, of which the oft-cited eBooster is an example. The filtered electric energy is then sent to the device 40. The third branch from the power supply 20 extends to a CAN-Bus card 55. This card 55 collects and interprets the voltage and current data from the power supply 20 and transmits it to the car control unit 50. The car control unit 50, in turn, receives this data and uses it to manage the vehicle's operations. Lastly, the car control unit 50 provides an analog output to the control bench 60, which interprets the data to further optimize the efficiency and performance of the vehicle.

[0026] It is clear that modifications, additions or variations that are obvious to a person skilled in the art can be made to the invention described so far, without thereby departing from the scope of protection provided by the attached claims.

Claims

Claims1. Optimized power and management system with advanced voltage control for vehicle devices at 48V, characterized in that it comprises:- at least a transformer (10), located at the input of the system and capable of converting electric energy at a high voltage of 400 V to a lower and manageable voltage of 45 V;- at least a power supply unit with IGBT technology (20), which in turn includes at least 4 IGBT units protected by optimized RC filters, is capable of supplying a current of up to 150A and a voltage of 48 V within a minimum tolerance, is arranged downstream of said transformer (10) to receive energy from it and uses an H-bridge to maintain a cos(|> of 0,98, by ensuring a low voltage ripple and implementing a feedback circuit for real-time control of the supply voltage;- Zehner filters e inductors (30) arranged in the power supply circuit and designed to prevent voltage peaks and ensure a stable power supply;- at least a Programmable Logic Controller (PLC) (100), programmed with custom software and designed to monitor and manage the system through power control and monitoring of parameters such as voltage and current from the power supply (20).

2. Optimized power and management system with advanced voltage control for vehicle devices at 48V, according to the preceding claim characterized in that said transformer (10) is suitable for the function of isolation, allowing the negative pole of the motor to be grounded.

3. Optimized power and management system with advanced voltage control for vehicle devices at 48V, according to anyone of the preceding claims, characterized in that it comprises a CAN-Bus card (55) capable of collecting voltage and current data from said power supply (20) and of transmitting them to a remote control unit (50); said control unit (50) providing an analog output to a control bench (60) through transducers; said transducers providing an analog output of 0-5V, with acquisitions every 250ms.

4. Optimized power and management system with advanced voltage control for vehicle devices at 48 V, according to anyone of the preceding claims, characterized in that said PLC is also adapted for allowing users to load or modify control algorithms through a touch-screen interface with Ethernet connection, making the system adaptable to different 48V vehicular devices.

5. Optimized power and management system with advanced voltage control for vehicledevices at 48V, according to anyone of the preceding claims, characterized in that it comprises a mixed-flow cooling system capable of maintaining the temperature of the IGBTs and other components between 25°C and 40°C, which in turn includes finned aluminum heat sinks, variable speed fans, and a liquid cooling system with radiator and pumps, which is monitored and controlled by said PLC (100) by means of thermocouple sensors.

6. Optimized power and management system with advanced voltage control for vehicle devices at 48 V, according to anyone of the preceding claims, characterized in that said transformer (10) is optimized with a silicon iron alloy core with high permeability, low- resistance windings with high purity copper cables, and a magnetic shielding system to reduce magnetic leakage, capable of reaching an operational efficiency of more than 97%.

7. Optimized power and management system with advanced voltage control for vehicle devices at 48V, according to anyone of the preceding claims, characterized in that it comprises protection mechanisms such as automatic circuit breakers having a response time of less than 5 milliseconds and varistors with an energy absorption capacity of at least 40J, to prevent damage to the system caused by overcurrent or overvoltage, wherein said PLC (100) monitors and reacts to overcurrent and overvoltage events through the isolation of sections of the circuit or the regulation of operating parameters.

Images