An ultra-low voltage high-power bidirectional digital DC-DC power supply module and a control method thereof

Abstract

The application provides an ultra-low-voltage high-power bidirectional digital DC-DC power supply module and a control method thereof, relates to the technical field of power electronics, and obtains control demand information, analyzes and judges the charging and discharging degree according to the control demand information, analyzes and judges module scheduling control type information, obtains first module scheduling control type information, and further obtains module control adjustment information; demand completion and change analysis is carried out according to the module control adjustment information, demand update information is obtained, second module scheduling control type information is obtained according to the demand update information, front and rear control type similarity and difference analysis is carried out, control difference information and connection strip adjustment data are obtained according to the similarity and difference analysis data, buffer setting adjustment is carried out, scheduling adjustment control data is obtained, and flexible and intelligent switching control of the power supply module is realized.

Description

Technical Field

[0001] This invention proposes an ultra-low voltage high-power bidirectional digital DC-DC power supply module and its control method, which relates to the field of power electronics technology, specifically to the field of control technology for bidirectional digital DC-DC power supply modules. Background Technology

[0002] In traditional technologies, whether it is flyback, forward, or half-bridge / full-bridge circuits, power supply circuits are rarely designed in parallel, and they have ultra-low voltage input characteristics. Moreover, no single product uses multiple circuit technologies.

[0003] Traditional bidirectional DC-DC converters often use a single topology. The half-bridge topology is prone to increased losses due to excessive current stress when the input voltage is 1.6V. The full-bridge topology is difficult to meet the requirements of high-frequency fast switching and cannot take into account both ultra-low voltage adaptation and fast response, resulting in limited conversion performance in ultra-low voltage and high current scenarios.

[0004] Meanwhile, existing modules are mostly designed for single functions. Solutions that emphasize rapid switching experience significantly increased losses under light load conditions (e.g., 5W), while solutions that emphasize energy saving cannot achieve high-power parallel operation. This necessitates frequent switching of different functional modules when switching between various scenarios such as drone take-off and landing, energy storage standby, and electric vehicle charging. This not only complicates operation but also significantly increases equipment costs and maintenance difficulty. Traditional solutions generally use fixed buffer parameters during module switching, which can easily lead to voltage fluctuations exceeding 3V when facing large-difference switching. This makes it difficult to meet the stringent requirements of drone sensors and medical equipment for zero fluctuations, greatly limiting their application scope in highly sensitive scenarios. Summary of the Invention

[0005] This invention provides an ultra-low voltage, high-power, bidirectional digital DC-DC power supply module and its control method to solve the above-mentioned problems:

[0006] This invention proposes an ultra-low voltage high-power bidirectional digital DC-DC power module and its control method. The power module includes: a power supply, a bidirectional DC-DC converter, and a load. The power supply and the bidirectional DC-DC converter perform bidirectional power transmission, and the bidirectional DC-DC converter and the load perform bidirectional power transmission.

[0007] The bidirectional DC-DC converter is also connected to the display screen, the 485 communication module, the power on / off switch, and the fan interface, respectively.

[0008] The bidirectional DC-DC converter includes a fast switching module, a power-saving module, a capacity expansion module, and a digital controller.

[0009] The fast switching module, power saving module, and capacity expansion module are respectively connected to the digital controller via bidirectional communication.

[0010] The power module is controlled by a fast switching module, a power-saving module, a capacity expansion module, and a digital controller.

[0011] Furthermore, the fast switching module, power-saving module, and capacity expansion module are respectively bidirectionally connected to the digital controller, including:

[0012] The fast switching module includes a dual push-pull module and a half-bridge module, used for fast switching control;

[0013] The power-saving module includes a full-bridge module and an auxiliary inductor module, which are used for energy-saving standby control.

[0014] The expansion module includes a BUCK module and a current sharing module, which are used for multi-channel current sharing control.

[0015] The digital controller is used for module scheduling control of the fast switching module, power saving module and capacity expansion module.

[0016] Furthermore, the method includes:

[0017] S1. Obtain control requirement information, and perform charge / discharge level analysis and determination and module scheduling control type information analysis and determination based on the control requirement information to obtain the first module scheduling control type information, and then obtain module control adjustment information.

[0018] S2. Based on the module control adjustment information, perform demand completion and change analysis to obtain demand update information. Based on the demand update information, obtain the second module scheduling control type information, perform before and after control type difference analysis, obtain control difference information and its connection bar adjustment data based on the difference analysis data, perform buffer setting adjustment, and obtain scheduling adjustment control data.

[0019] Further, S1 includes:

[0020] Control requirements information is obtained through the 485 communication module;

[0021] Based on the control requirement information, charge / discharge determination is performed to obtain charge / discharge determination information;

[0022] The degree of control requirement information is determined to obtain degree determination information.

[0023] The charging and discharging degree is determined by combining the charging and discharging determination information with the degree determination information to obtain the charging and discharging degree determination information.

[0024] Based on the charging and discharging level determination information, the first module scheduling and control type information is obtained. Based on the first module scheduling and control type information, the power module is controlled and adjusted to obtain module control and adjustment information.

[0025] Further, the degree of charge / discharge is determined by combining the charge / discharge determination information with the degree determination information to obtain charge / discharge degree determination information, including:

[0026] Based on the charging and discharging determination, control the power direction and trigger the power direction control command;

[0027] Based on the degree determination information, control the power data and trigger power quantity control commands;

[0028] The direction and data of the control power are determined based on the degree of charging and discharging, and the power direction and quantity control commands are generated based on the power direction control commands and the power quantity control commands.

[0029] The power charging and discharging level is determined based on the power direction quantity control command, and the charging and discharging level determination information is obtained.

[0030] Furthermore, the step of obtaining the first module scheduling control type information based on the charge / discharge level determination information includes:

[0031] The type of charge / discharge control is determined based on the information regarding the degree of charge / discharge.

[0032] The degree of charge / discharge control is determined based on the information on the degree of charge / discharge.

[0033] Based on the type of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a module selection option.

[0034] Based on the degree of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a degree-selection module.

[0035] The category selection module and the degree selection module establish a rule mapping table, and the scheduling control category information of the first module is determined according to the rule mapping table.

[0036] Further, S2 includes:

[0037] Based on the module control adjustment information and control requirement information, obtain requirement completion information and requirement incomplete information;

[0038] Based on the information on completed and uncompleted requirements, determine whether the requirements have been completed and obtain requirement judgment information;

[0039] Based on the demand judgment information, a demand collection instruction is triggered, and the demand collection is controlled according to the demand collection instruction to obtain the demand update information;

[0040] Obtain charging and discharging level determination information and its second module scheduling and control type information for demand update information;

[0041] Based on the scheduling control type information of the first module and the scheduling control type information of the second module, scheduling adjustment analysis is performed to obtain scheduling adjustment analysis data;

[0042] Based on the scheduling and adjustment analysis data, scheduling and adjustment control are carried out to obtain scheduling and adjustment control data.

[0043] Furthermore, the step of performing scheduling adjustment analysis based on the scheduling control type information of the first module and the scheduling control type information of the second module to obtain scheduling adjustment analysis data includes:

[0044] Determine whether the scheduling control type information of the first module is the same as that of the scheduling control type information of the second module, and obtain the type determination information;

[0045] When the category judgment information is the same, no module control switching will be performed;

[0046] When the category judgment information is different, the switching command controlled by the module is triggered.

[0047] Furthermore, the step of performing scheduling and control based on scheduling and control analysis data to obtain scheduling and control data includes:

[0048] Based on the switching instructions of module control, obtain the control difference information between the scheduling control type information of the first module and the scheduling control type information of the second module;

[0049] The ratio of the control difference information to the preset control difference threshold is obtained to obtain the control difference coefficient;

[0050] The control difference buffer coefficient is obtained based on the control difference coefficient, and the module control is switched based on the control difference buffer coefficient to obtain scheduling and adjustment control data.

[0051] Further, a control difference buffer coefficient is obtained based on the control difference coefficient, and module control switching is performed based on the control difference buffer coefficient to obtain scheduling and adjustment control data, including:

[0052] Establish a preset control connecting strip, and adjust the length of the preset control connecting strip according to the control difference coefficient to obtain the connecting strip adjustment data;

[0053] The pre-adjustment starting point of the first module's scheduling control type information and the pre-adjustment ending point of the second module's scheduling control type information are determined based on the connection bar adjustment data.

[0054] Connect the pre-adjustment start point and the pre-adjustment end point to obtain a switching control buffer band;

[0055] Obtain the ratio of the length of the switching control buffer band to the control difference coefficient to obtain the control difference buffer coefficient;

[0056] The switching control buffer band is adjusted multiple times based on the control difference buffer coefficient to obtain scheduling adjustment control data.

[0057] The beneficial effects of this invention are as follows: This invention solves the technical challenge of high-power output from ultra-low input voltage (1.5V), and also enables bidirectional charging and discharging. It addresses applications such as mobile energy storage, drone propulsion, and electric vehicle propulsion, providing a solution for distributed power supply layouts. Furthermore, it allows for module paralleling to increase input and output power. This invention integrates technologies such as dual push-pull drive, half-bridge soft switching, synchronous rectification, and BUCK step-down circuits, and also employs electrical paralleling technology to achieve high-power output through bidirectional charging and discharging. The discharge characteristic allows for a minimum input voltage of 1.6V, and the output voltage can be adjusted to various ranges without hardware modifications, such as 12V to 72V, with a continuous output power of up to 600W. The charging characteristic allows for wide-range input voltage conversion from 12V to 72V to charge batteries (3.6V when fully charged), with a continuous charging output power of up to 600W. This invention solves the unidirectional problem of traditional DC-DC converters that can only discharge or only charge. A single module can achieve discharge from 1.6V to 48V (for example) and charging from 48V to 3.6V (for example), adapting to scenarios requiring bidirectional power replenishment, such as mobile energy storage and drones. The auxiliary interfaces cover status monitoring (display screen), remote control / parallel control (485 communication module), start / stop management (power on / off), and thermal performance protection (such as fan or thermal protection), meeting the needs of industrial equipment for monitoring, controllability, and high reliability. The core functions are split into three workshops and a dispatcher, laying the foundation for on-demand dispatching and fault replacement, and reducing maintenance costs. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of a control method for an ultra-low voltage, high-power, bidirectional digital DC-DC power supply module.

[0059] Figure 2 This is a schematic diagram of an ultra-low voltage, high-power, bidirectional digital DC-DC power supply module. Detailed Implementation

[0060] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0061] In one embodiment of the present invention, an ultra-low voltage high-power bidirectional digital DC-DC power supply module and its control method are proposed. The power supply module includes: a power supply, a bidirectional DC-DC converter, and a load. The power supply and the bidirectional DC-DC converter perform bidirectional power transmission, and the bidirectional DC-DC converter and the load perform bidirectional power transmission.

[0062] The bidirectional DC-DC converter is also connected to the display screen, the 485 communication module, the power on / off switch, and the fan interface, respectively. Figure 2 As shown.

[0063] The bidirectional DC-DC converter includes a fast switching module, a power-saving module, a capacity expansion module, and a digital controller.

[0064] The fast switching module, power saving module, and capacity expansion module are respectively connected to the digital controller via bidirectional communication.

[0065] The power module is controlled by a fast switching module, a power-saving module, a capacity expansion module, and a digital controller.

[0066] Multiple product series can be derived by controlling the power module to obtain the target output power.

[0067] This invention enables some functions of the BDC600_R1 series, a high-efficiency, ultra-low voltage input bidirectional DC-DC switching power supply. It can charge and discharge bidirectionally, supporting nominal 3.6V batteries of 200A, 280A, and 314A as input. A single unit can continuously output up to 600W. It can also be used in parallel for discharge output, achieving the total power output after parallel operation. Furthermore, it can be controlled independently using RS-485 communication. It is widely used in DC-DC distributed power supply applications such as energy storage systems, motor drives, robots, drones, communication base stations, and AI server backup power supplies.

[0068] The working principle and technical effect of the above technical solution are as follows: the power supply (such as a 3.6V lithium battery or a 48V external power supply) is an energy warehouse, the load (such as a drone motor or a 3.2V battery) is an energy user, and the bidirectional DC-DC converter is an intelligent transfer station.

[0069] Two-way transmission is manifested as from warehouse to transfer station to user (discharging, such as the battery powering the motor), and from user to transfer station to warehouse (charging, such as external power supply to the battery).

[0070] The display screen (to check the status of the relay station), 485 communication (for the relay station to communicate with external devices), power on / off (main power switch for the relay station), and fan interface (for heat dissipation of the relay station) are auxiliary tools to ensure the normal operation of the relay station;

[0071] The fast switching, power saving, and capacity expansion modules are the three functional workshops of the transfer station. The digital controller is the dispatcher, which communicates with the three workshops in real time and starts the corresponding workshops as needed.

[0072] This invention solves the unidirectional problem of traditional DC-DC converters that can only discharge or only charge. The same module can achieve 1.6V to 48V discharge and 48V to 3.6V charging, making it suitable for scenarios that require bidirectional power replenishment, such as mobile energy storage and drones.

[0073] The auxiliary interfaces cover status monitoring (display screen), remote control (485 communication module), start / stop management (power on / off), and heat dissipation protection (fan), meeting the requirements of industrial equipment for monitoring, controllability, and high reliability.

[0074] The core functions are broken down into three workshops and a dispatcher, laying the foundation for on-demand dispatching and fault replacement, and reducing maintenance costs (e.g., if the power-saving module fails, only the module needs to be replaced).

[0075] In one embodiment of the present invention, the fast switching module, power-saving module, and capacity expansion module are respectively bidirectionally connected to the digital controller, comprising:

[0076] The fast switching module includes a dual push-pull module and a half-bridge module, used for fast switching control;

[0077] The power-saving module includes a full-bridge module and an auxiliary inductor module, which are used for energy-saving standby control.

[0078] The expansion module includes a BUCK module and a current sharing module, which are used for multi-channel current sharing control.

[0079] The digital controller is used for module scheduling control of the fast switching module, power saving module and capacity expansion module.

[0080] The working principle and technical effects of the above technical solution are as follows: The dual push-pull module acts like a low-voltage, high-current conveyor belt, which can efficiently aggregate small energy packets of 1.6V; the half-bridge module acts like a high-frequency switching gate, which can quickly boost and deboost the energy packets to achieve rapid switching from discharge to charging; the full-bridge module acts like a low-friction conveyor belt, and the auxiliary inductor acts like an energy buffer. Under light load (such as charging a mobile phone at 5W), the conveyor belt runs at low speed and has low friction, and the auxiliary inductor reduces energy waste and achieves low-power standby; the BUCK module acts like a high-voltage step-down gate, which can split a large 48V energy packet into a small 3.2V energy packet; the current sharing module acts like a multi-channel shunt, which allows the energy packets of multiple transfer stations to be output evenly; the digital controller sends instructions to three (or more) workshops in real time through bidirectional communication (such as a 485 bus) (such as starting a fast switching workshop), and at the same time receives feedback from the workshops (such as the current power of 500W) to ensure that the workshops work as required.

[0081] The three workshops correspond to the three core requirements of rapid switching, energy saving, and capacity expansion, avoiding the inefficiency of one workshop doing all the work; two-way communication ensures a closed loop from instruction issuance to execution feedback, avoiding the risk of the dispatcher issuing the wrong instruction and the workshop not responding (if the capacity expansion module does not receive the flow sharing instruction, the dispatcher can reissue it to improve control accuracy); targeted design reduces losses in various scenarios.

[0082] In one embodiment of the present invention, the method includes:

[0083] S1. Obtain control requirement information, and perform charge / discharge level analysis and determination and module scheduling control type information analysis and determination based on the control requirement information to obtain the first module scheduling control type information, and then obtain module control adjustment information.

[0084] S2. Based on the module control adjustment information, perform demand completion and change analysis to obtain demand update information. Based on the demand update information, obtain the second module scheduling control type information, perform a difference analysis of the control types before and after, obtain control difference information and its connection bar adjustment data based on the difference analysis data, perform buffer setting adjustment, and obtain scheduling adjustment control data, such as... Figure 1 As shown.

[0085] The working principle and technical effect of the above technical solution are as follows: The dispatcher first inquires about the demand through 485 communication, analyzes whether it is charging or discharging (direction) and how much power is needed (degree), and then starts the corresponding workshop (such as a fast-switching workshop) to allow the transfer station to work according to the demand; the dispatcher continuously monitors changes in demand (such as when a drone lands, the demand changes from discharging 500W to charging 50W), and determines whether it is necessary to switch workshops (from fast switching to power saving). If a switch is required, the parameter differences between the two workshops are calculated (such as voltage from 48V to 3.2V, power from 500W to 50W), and the buffer settings are adjusted (such as adding supercapacitors for energy replenishment) to ensure a smooth switch.

[0086] This method solves the problem that traditional modules operate according to fixed parameters once started. For example, mobile energy storage can automatically switch between daytime discharge (500W) and nighttime standby (5W) without manual intervention.

[0087] S2's differential analysis and buffer adjustment avoid current interruption and overcurrent during switching. For example, when switching from fast switching to power saving switching, the voltage fluctuation drops from 3V to 0.5V, meeting the zero fluctuation requirements of sensitive devices such as drone sensors.

[0088] A closed loop is formed from demand acquisition to initial scheduling to demand update to secondary scheduling, avoiding energy waste when the module continues to operate with the original parameters even when the demand changes.

[0089] In one embodiment of the present invention, S1 includes:

[0090] Control requirements information is obtained through the 485 communication module;

[0091] Based on the control requirement information, charge / discharge determination is performed to obtain charge / discharge determination information;

[0092] The degree is determined based on the control requirement information to obtain degree determination information; the degree determination is a power magnitude determination.

[0093] The charging and discharging degree is determined by combining the charging and discharging determination information with the degree determination information to obtain the charging and discharging degree determination information.

[0094] Based on the charge / discharge level determination information, the scheduling and control type information of the first module is obtained. Then, the power module's control and adjustment are performed according to this information to obtain module control and adjustment information. The redundancy determination in this method facilitates the acquisition of individual and overall information during subsequent tracing.

[0095] The working principle and technical effect of the above technical solution are as follows: The dispatcher receives external instructions (such as the drone motor requiring 48V / 500W power) through 485 communication, which is the control demand information; analyzes whether the demand is discharging (from warehouse to user, such as the battery powering the motor) or charging (from user to warehouse, such as external power supply to the battery), and obtains charging and discharging determination information; analyzes the power level of the demand (such as 500W is medium power, 5W is light power), and obtains degree determination information; combines the direction and degree to select the workshop (such as discharging and medium power to quickly switch workshops), and obtains the first module dispatch information, while recording the direction determination process and degree determination process (redundant design) for easy traceability (such as when a problem occurs, it can be found whether the direction judgment is wrong or the degree judgment is wrong).

[0096] The decision is made in two steps: direction and degree. This avoids the mistake of choosing the wrong option by only looking at the direction and not the degree (e.g., if you choose the fast switching workshop for charging and light power, the loss will be higher than that for the power saving workshop).

[0097] The redundant design records every decision-making step, solving the pain point of difficult fault location in industrial equipment (such as selecting the wrong module, it can be checked whether the direction judgment is wrong or the degree judgment is wrong, which greatly improves maintenance efficiency).

[0098] Individual information (such as only the direction determination result) and overall information (direction and degree determination process) can be obtained separately, which is convenient for engineers to debug (for example, when debugging, only check whether the direction determination is correct, without needing to look at the overall process).

[0099] In one embodiment of the present invention, the degree of charge / discharge is determined by combining the charge / discharge determination information with the degree determination information to obtain the charge / discharge degree determination information, including:

[0100] Based on the charging and discharging determination, control the power direction and trigger the power direction control command;

[0101] Based on the degree determination information, control the power data and trigger power quantity control commands;

[0102] The direction and data of the control power are determined based on the degree of charging and discharging, and the power direction and quantity control commands are generated based on the power direction control commands and the power quantity control commands.

[0103] The power charging and discharging level is determined based on the power direction quantity control command, and the charging and discharging level determination information is obtained.

[0104] The redundancy determination in this method facilitates the acquisition of single information and overall information during subsequent tracing.

[0105] The working principle and technical effect of the above technical solution are as follows: if the demand is to discharge, a power direction control command is triggered (such as energy flowing from the 1.6V battery to the 48V motor); if the demand is to charge, a power direction control command is triggered (such as energy flowing from the 48V external power supply to the 3.2V battery).

[0106] If the required power is 500W, a power quantity control command is triggered (e.g., output power 500W); if the required power is 5W, a power quantity control command is triggered (e.g., output power 5W).

[0107] The direction command and quantity command are combined into a power direction quantity control command (such as discharge and 500W). Based on this, the charging and discharging level information is determined, and the direction command generation process and quantity command generation process are recorded (redundant design).

[0108] The degree determination is broken down into direction and quantity instructions to avoid judgment errors caused by ambiguous instructions (e.g., saying only 500W without specifying the direction may lead to the wrong workshop being selected).

[0109] The generation process of each instruction is recorded. If a judgment error occurs later, it can be accurately located (e.g., if the direction instruction is wrong, it is found that the requirement parsing is wrong; if the quantity instruction is wrong, it is found that the power calculation is wrong), which greatly shortens the fault location time.

[0110] The unified instruction format (such as direction instructions and quantity instructions) lays the foundation for module adaptation (if a new module is added, only the unified instructions need to be recognized, and there is no need to redesign the judgment logic).

[0111] In one embodiment of the present invention, obtaining the first module scheduling control type information based on the charge / discharge level determination information includes:

[0112] The type of charge / discharge control is determined based on the information regarding the degree of charge / discharge.

[0113] The degree of charge / discharge control is determined based on the information on the degree of charge / discharge.

[0114] Based on the type of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a module selection option.

[0115] Based on the degree of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a degree-selection module.

[0116] A rule mapping table is established for the category selection module and the degree selection module. Based on this rule mapping table, the scheduling control category information for the first module is determined. Priority can be set by judging whether they are the same.

[0117] The working principle and technical effect of the above technical solution are as follows: the control type (discharge, charge) and control level (medium power, light power, high power) are extracted from the charge and discharge level information.

[0118] Select workshops by type (e.g., discharge to fast switching, capacity expansion workshop) and by degree (e.g., medium power to fast switching workshop) to obtain type selection module and degree selection module;

[0119] Establish a rule mapping table (e.g., from selecting fast switching for type and fast switching for degree to selecting fast switching for certainty; from selecting fast switching for type and power saving for degree to selecting by priority, such as power saving for degree priority); the rule mapping table can be determined based on historical experience of individual workshops.

[0120] The scheduling information for the first module is determined based on the rule table (e.g., priority by degree, charging and light power to power saving workshop).

[0121] The rule mapping table unifies the selection logic, avoiding the confusion of different engineers selecting different workshops (if the same requirement exists, A selects fast switching and B selects power saving, but selecting according to the table ensures uniformity).

[0122] Priority design adapts to complex scenarios (such as discharge and medium-to-high power boundary value of 500W; if efficiency is prioritized, fast switching can be selected; if stability is prioritized, capacity expansion can be selected; settings can be configured as needed).

[0123] When adding a new module, you only need to add the mapping of type and degree to the new module in the rule table, without modifying the overall logic (e.g., to add a super fast charging module, simply add charging and 1000W to the super fast charging module), which greatly reduces the expansion cost.

[0124] In one embodiment of the present invention, S2 includes:

[0125] Based on the module control adjustment information and control requirement information, obtain requirement completion information and requirement incomplete information;

[0126] Based on the information on completed and uncompleted requirements, determine whether the requirements have been completed and obtain requirement judgment information;

[0127] Based on the demand judgment information, a demand collection instruction is triggered, and the demand collection is controlled according to the demand collection instruction to obtain the demand update information;

[0128] Obtain charging and discharging level determination information and its second module scheduling and control type information for demand update information;

[0129] Based on the scheduling control type information of the first module and the scheduling control type information of the second module, scheduling adjustment analysis is performed to obtain scheduling adjustment analysis data;

[0130] Based on the scheduling and adjustment analysis data, scheduling and adjustment control are carried out to obtain scheduling and adjustment control data.

[0131] The working principle and technical effect of the above technical solution are as follows: the dispatcher checks whether the current workshop meets the demand (such as whether the power supply to the motor in the workshop is quickly switched to 48V / 500W) and obtains the demand completion information (completed) or demand incomplete information (not completed).

[0132] If the demand changes (e.g., the motor stops, the demand drops from 500W to 0W, and then the battery needs to be charged at 3.2V / 50W), a demand acquisition command is triggered to obtain the updated demand information.

[0133] Based on the updated requirements, the second module scheduling information (such as charging and light power to power saving workshop) is obtained.

[0134] The system compares the first module (fast switching) and the second module (power saving) to see if they are the same. If they are the same, the system does not switch; otherwise, it triggers a switching command. Switching only occurs after this process is complete.

[0135] Continuously monitor changes in demand to avoid energy waste caused by not responding to changes in demand (e.g., if demand drops from 500W to 5W, an additional 0.125 kWh of electricity will be wasted per hour if the system is not switched).

[0136] Do not switch between the same modules to reduce unnecessary operations (e.g., if the demand drops from 500W to 480W, the quick switch shop can still be used without switching, thus reducing switching losses).

[0137] Switch only when modules are different to avoid circuit fluctuations caused by frequent switching (such as multiple switching within 1 minute, which may cause voltage jumps and affect the life of the equipment).

[0138] In one embodiment of the present invention, the step of performing scheduling adjustment analysis based on the scheduling control type information of the first module and the scheduling control type information of the second module to obtain scheduling adjustment analysis data includes:

[0139] Determine whether the scheduling control type information of the first module is the same as that of the scheduling control type information of the second module, and obtain the type determination information;

[0140] When the category judgment information is the same, no module control switching will be performed;

[0141] When the category judgment information is different, the switching command controlled by the module is triggered.

[0142] The working principle and technical effect of the above technical solution are as follows: If it is necessary to switch from the fast switching workshop (48V / 500W) to the power saving workshop (3.2V / 50W), calculate the control difference information between the two (voltage difference 44.8V, power difference 450W).

[0143] Divide the difference information by the preset threshold (e.g., voltage threshold 50V, power threshold 500W) to obtain the control difference coefficient (voltage coefficient 44.8 / 50=0.896, power coefficient 450 / 500=0.9).

[0144] Calculate the control difference buffer coefficient based on the difference coefficient (the larger the difference coefficient, the larger the buffer coefficient to avoid fluctuations). For example, the voltage coefficient is 0.896 to the buffer coefficient is 0.9, and the power coefficient is 0.9 to the buffer coefficient is 0.92. Take the larger value of 0.92 as the final buffer coefficient.

[0145] Adjust the circuit according to the buffer coefficient (such as adding the discharge amount of the supercapacitor to extend the buffer time) to ensure smooth switching.

[0146] The fluctuation risk is quantified by the difference coefficient, and the buffer coefficient is adjusted in a targeted manner to avoid the interruption and overcurrent when switching directly with large differences (e.g., if the voltage difference is 44.8V, the voltage will jump by 3V when switching without buffering, but will jump by 0.5V after buffering).

[0147] Different difference coefficients and different buffer coefficients are used to adapt to different switching scenarios (e.g., small difference: fast switch to fast switch fine-tuning, buffer coefficient 0.3; large difference: fast switch to power saving, buffer coefficient 0.9), avoiding the waste of buffering with a one-size-fits-all approach;

[0148] Precise buffering reduces energy waste (e.g., during large-scale switching, excessive buffering increases losses significantly; insufficient buffering increases volatility risk; precise buffering balances both, with only a small increase in losses).

[0149] In one embodiment of the present invention, the step of performing scheduling and control based on scheduling and control analysis data to obtain scheduling and control data includes:

[0150] Based on the switching instructions of module control, obtain the control difference information between the scheduling control type information of the first module and the scheduling control type information of the second module;

[0151] The ratio of the control difference information to the preset control difference threshold is obtained to obtain the control difference coefficient;

[0152] The control difference buffer coefficient is obtained based on the control difference coefficient, and the module control is switched based on the control difference buffer coefficient to obtain scheduling and adjustment control data.

[0153] The working principle and technical effect of the above technical solution are as follows: establish a preset control connection strip (such as a strip representing voltage change, with the starting point being 48V in the fast switching workshop and the ending point being 3.2V in the power saving workshop).

[0154] Adjust the length of the connecting strip according to the control difference coefficient (e.g., 0.9) (a large coefficient results in a long strip and a long buffer time; a small coefficient results in a short strip and a short buffer time) to obtain the connecting strip adjustment data;

[0155] Based on the adjustment data, determine the pre-adjustment starting point (e.g., 48V to 47V, reduce by 1V in advance) and the pre-adjustment ending point (e.g., 3.2V to 3.5V, increase by 0.3V in advance). The area between the two points is the switching control buffer zone (47V to 3.5V).

[0156] Divide the buffer band length (47-3.5=43.5V) by the difference coefficient (0.9) to obtain the control difference buffer coefficient (43.5 / 0.9≈48.3).

[0157] Adjust the buffer band multiple times according to the buffer coefficient (e.g., after the first adjustment, the voltage fluctuates by 0.8V, and the second adjustment is made to 0.5V until the requirements are met) to obtain the scheduling and control data.

[0158] The buffer band design allows parameters to transition gradually (e.g., from 48V to 47V to 45V to ... to 3.5V to 3.2V), rather than jumping directly. This results in small voltage and current fluctuations during switching, meeting the zero-fluctuation requirements of drone sensors, medical equipment, and other devices.

[0159] Multiple adjustments avoid the problem of insufficient adjustment in one go (e.g., a single adjustment causes a fluctuation of 0.8V, which does not meet the 0.5V requirement, but multiple adjustments can achieve the target), greatly improving the success rate of switching.

[0160] The buffer design is independent of specific modules and can adapt to all module switching (such as fast switching to expansion, power saving to expansion), without the need to design a separate buffer for each type of switching, thus reducing design complexity.

[0161] In one embodiment of the present invention, a control difference buffer coefficient is obtained based on the control difference coefficient, and module control switching is performed based on the control difference buffer coefficient to obtain scheduling and adjustment control data, including:

[0162] Establish a preset control connecting strip, and adjust the length of the preset control connecting strip according to the control difference coefficient to obtain the connecting strip adjustment data;

[0163] The pre-adjustment starting point of the first module's scheduling control type information and the pre-adjustment ending point of the second module's scheduling control type information are determined based on the connection bar adjustment data.

[0164] Connect the pre-adjustment start point and the pre-adjustment end point to obtain a switching control buffer band;

[0165] Obtain the ratio of the length of the switching control buffer band to the control difference coefficient to obtain the control difference buffer coefficient;

[0166] The switching control buffer band is adjusted multiple times based on the control difference buffer coefficient to obtain scheduling adjustment control data.

[0167] The working principle and technical effect of the above technical solution are as follows: First, a preset control connection bar is established, which can be understood as the basic buffer channel when switching between transfer stations. For example, the default length corresponds to a normal switching scenario with a voltage difference of 10V and a power difference of 100W, ensuring basic buffer capacity.

[0168] Based on the previously calculated control difference coefficient (e.g., a coefficient of 0.9 corresponding to a voltage difference of 44.8V and a power difference of 450W), adjust the length of the preset control connecting bar. The larger the difference coefficient (the higher the risk of switching fluctuations), the longer the connecting bar (the wider the buffer channel). For example, when the coefficient is 0.9, the length of the connecting bar is extended by 90% compared to the default value, reserving sufficient buffer space for large difference switching.

[0169] Based on the adjusted connection bar data, determine the pre-adjustment starting point (the current module's parameter fine-tuning value, such as reducing the voltage by 1V in advance to avoid a sudden voltage drop during the switch from 48V to 47V in the workshop) and the pre-adjustment ending point (the target module's parameter pre-adjustment value, such as increasing the voltage by 0.3V in advance to reduce the parameter drop during the switch from 3.2V to 3.5V in the power-saving workshop).

[0170] Divide the switching control buffer band length (e.g., 47V-3.5V=43.5V) by the control difference coefficient (0.9) to obtain the control difference buffer coefficient (43.5÷0.9≈48.3). This coefficient represents the buffer strength required per unit difference. The larger the coefficient, the smoother the buffer.

[0171] The buffer band is fine-tuned multiple times based on the buffer coefficient. For example, if the voltage fluctuation is 0.8V after the first adjustment, which does not reach the target of ≤0.5V, the connecting strip is further shortened according to the buffer coefficient (e.g., the 43.5V buffer band is divided into 5 segments, and each segment is adjusted by 0.9V) until the fluctuation reaches the target, and finally the scheduling and adjustment control data is obtained.

[0172] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A control method for an ultra-low voltage, high-power, bidirectional digital DC-DC power supply module, characterized in that, The power module includes: a power supply, a bidirectional DC-DC converter, and a load. The power supply and the bidirectional DC-DC converter transmit power bidirectionally, and the bidirectional DC-DC converter transmits power bidirectionally to the load. The bidirectional DC-DC converter is also connected to the display screen, the 485 communication module, the power on / off switch, and the fan interface, respectively. The bidirectional DC-DC converter includes a fast switching module, a power-saving module, a capacity expansion module, and a digital controller. The fast switching module, power saving module, and capacity expansion module are respectively connected to the digital controller via bidirectional communication. The power module is controlled through a fast switching module, a power-saving module, a capacity expansion module, and a digital controller. The control method includes: S1. Obtain control requirement information, and perform charge / discharge level analysis and determination and module scheduling control type information analysis and determination based on the control requirement information to obtain the first module scheduling control type information, and then obtain module control adjustment information. S2. Based on the module control adjustment information and control requirement information, obtain requirement completion information and requirement incomplete information; Based on the information on completed and uncompleted requirements, determine whether the requirements have been completed and obtain requirement judgment information; Based on the demand judgment information, a demand collection instruction is triggered, and the demand collection is controlled according to the demand collection instruction to obtain the demand update information; Obtain the charging / discharging level determination information and its corresponding second module scheduling and control type information for demand update information; Based on the scheduling control type information of the first module and the scheduling control type information of the second module, scheduling adjustment analysis is performed to obtain scheduling adjustment analysis data; Based on the scheduling and adjustment analysis data, scheduling and adjustment control are performed to obtain scheduling and adjustment control data; The step of performing scheduling and control based on scheduling and control analysis data to obtain scheduling and control data includes: Based on the switching instructions of module control, obtain the control difference information between the scheduling control type information of the first module and the scheduling control type information of the second module; The ratio of the control difference information to the preset control difference threshold is obtained to obtain the control difference coefficient; The control difference buffer coefficient is obtained based on the control difference coefficient, and the module control is switched based on the control difference buffer coefficient to obtain scheduling and adjustment control data. Specifically, the process includes obtaining a control difference buffer coefficient based on the control difference coefficient, performing module control switching based on the control difference buffer coefficient, and obtaining scheduling and adjustment control data, including: Establish a preset control connecting strip, and adjust the length of the preset control connecting strip according to the control difference coefficient to obtain the connecting strip adjustment data; The pre-adjustment starting point of the first module's scheduling control type information and the pre-adjustment ending point of the second module's scheduling control type information are determined based on the connection bar adjustment data. Connect the pre-adjustment start point and the pre-adjustment end point to obtain a switching control buffer band; Obtain the ratio of the length of the switching control buffer band to the control difference coefficient to obtain the control difference buffer coefficient; The switching control buffer band is adjusted multiple times based on the control difference buffer coefficient to obtain scheduling adjustment control data.

2. The control method for an ultra-low voltage high-power bidirectional digital DC-DC power supply module according to claim 1, characterized in that, The fast switching module, power saving module, and capacity expansion module are all bidirectionally connected to the digital controller, including: The fast switching module includes a dual push-pull module and a half-bridge module, used for fast switching control; The power-saving module includes a full-bridge module and an auxiliary inductor module, which are used for energy-saving standby control. The expansion module includes a BUCK module and a current sharing module, which are used for multi-channel current sharing control. The digital controller is used for module scheduling control of the fast switching module, power saving module and capacity expansion module.

3. The control method for an ultra-low voltage high-power bidirectional digital DC-DC power supply module according to claim 1, characterized in that, S1 includes: Control requirements information is obtained through the 485 communication module; Based on the control requirement information, the degree of charging and discharging is determined to obtain the degree of charging and discharging determination information. Based on the charging and discharging degree determination information, obtain the first module scheduling and control type information, and perform power module control and adjustment based on the first module scheduling and control type information to obtain module control and adjustment information; The process of determining the degree of charge / discharge based on the control requirement information to obtain charge / discharge degree determination information includes: Based on the combination of charging and discharging determination information and the degree of determination information, power direction control commands and power quantity control commands are triggered. Generate power direction and quantity control commands based on power direction control commands and power quantity control commands; The power charging and discharging level is determined based on the power direction quantity control command, and charging and discharging level determination information is obtained. The step of obtaining the first module scheduling control type information based on the charging / discharging level determination information includes: The type and degree of charge / discharge control are determined based on the information on the degree of charge / discharge. Based on the type of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a module selection option. Based on the degree of charge / discharge control, the module selection includes a fast switching module, a power-saving module, and a capacity expansion module, resulting in a degree-selection module. A rule mapping table is established based on the type selection module and the degree selection module, and the scheduling control type information of the first module is determined based on the rule mapping table.

4. The control method for an ultra-low voltage high-power bidirectional digital DC-DC power supply module according to claim 1, characterized in that, The process of performing scheduling adjustment analysis based on the scheduling control type information of the first module and the scheduling control type information of the second module to obtain scheduling adjustment analysis data includes: Determine whether the scheduling control type information of the first module is the same as that of the scheduling control type information of the second module, and obtain the type determination information; When the category judgment information is the same, no module control switching will be performed; When the category judgment information is different, the switching command controlled by the module is triggered.

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