Multi-channel electric tube integrated power supply system for high-power-density unmanned aerial vehicle

Abstract

The invention discloses a multipath electric tube integrated power supply system for a high-power-density unmanned aerial vehicle, and relates to the technical field of unmanned aerial vehicle power supply systems. The system comprises an input module for double-path isolation wide-voltage input, a pre-charging and discharging buffer matrix which is conducted in a grading manner and resists instantaneous large current, a power supply conversion module which is of a multi-topological structure and provides multi-path voltage output, and a multi-path load switch module which is in an all-solid-state design and comprises forty-four paths of channels, a control unit for monitoring and dispatching through a CAN bus and an output interface module adapted to a load through connectors of various specifications are used for cooperatively realizing high-power-density stable power supply; through grading conduction of the pre-charging and discharging buffer matrix, RC buffer cooperation, magnetic part co-integration topology, load priority dynamic distribution, special heat dissipation and vibration resistance and EMC optimization design, the device stably resists instantaneous large current impact, adapts to differential requirements of multiple types of loads, can quickly process faults and guarantee core power supply, and is high in reliability and high in reliability. And the system is compact in structure and can stably operate in an extreme environment.

Description

Technical Field

[0001] This invention relates to the field of unmanned aerial vehicle (UAV) power supply system technology, specifically a high-power-density UAV multi-channel integrated power supply system. Background Technology

[0002] With the widespread application of drone technology in various fields, the types of loads are becoming increasingly diverse, and power demands are continuously rising. A 2kW-class drone needs to simultaneously power multiple devices, including flight control, engine ECU, servo motors, and optoelectronic pods, with output voltages covering 12V, 24V, and 28V levels, and a total of 44 output channels. These drones also face challenges such as a 5ms 250A instantaneous current surge during start-up of the helical motor, short-term overload of the servo motor, and large power fluctuations under different loads. This places stringent requirements on the power supply system's shock resistance, power density, reliability, and environmental adaptability. As a core component of drones, the performance of the power supply system directly affects flight safety and mission completion quality. Developing an integrated power supply system that meets these requirements has become a key direction for industry development.

[0003] Traditional multi-channel power supply systems for drones have many limitations: when faced with instantaneous high current surges, they often rely on single-capacitor energy storage or simple resistor current limiting. The former struggles to quickly release ultra-high currents, while the latter generates significant heat and is prone to burning out components, neither of which can guarantee power supply stability. Power modules often employ independent magnetic component designs, resulting in bulky size, high weight, and insufficient power density, which does not meet the lightweight requirements of drones. Fault handling can only isolate faulty channels and cannot guarantee continuous power supply to core loads such as flight controllers and engine ECUs, potentially leading to flight risks. Furthermore, traditional systems have poor adaptability in terms of heat dissipation and vibration resistance design, resulting in significant power supply fluctuations in wide temperature ranges and high vibration environments, prominent electromagnetic interference issues, and difficulty in meeting the stability requirements of multi-load collaborative operation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a high-power-density multi-channel integrated power supply system for drones. This system utilizes a pre-charge and discharge buffer matrix with MOSFETs in a graded conduction phase and RC buffering, combined with a magnetic component co-integrated topology, dynamic load priority allocation, and optimized design for heat dissipation on an aluminum nitride ceramic substrate, silicone damping for vibration reduction, and EMC filtering. This allows the system to smoothly withstand the instantaneous high-current surge during start-up of the starter motor, accurately adapt to the differentiated power supply requirements of various load types, and quickly disconnect faulty channels and allocate redundant power in case of a fault, ensuring continuous power supply to core equipment. At the same time, the system has a compact structure to meet the lightweight requirements of drones, maintains stable performance in a wide temperature range and high vibration environment, and meets electromagnetic compatibility standards.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a high power density UAV multi-channel integrated power supply system, the system comprising an input module, a pre-charge and discharge buffer matrix, a power conversion module, a multi-channel load switch module, a control unit, and an output interface module; The input module accepts 20 to 32 volt DC input, corresponding to a 2 kW power requirement, with an input current of 62.5 amps to 100 amps. It includes a main input interface connected to the starter motor power supply circuit and a 7S lithium battery backup input interface, with dual-channel isolation via Schottky diodes. The pre-charge and discharge buffer matrix is ​​connected in series between the input module and the power conversion module. It includes an array of three sets of parallel N-channel enhancement-mode MOSFETs, an RC buffer network, and a buffer control unit. Each set of MOSFETs is connected in series with an independent RC branch. The buffer control unit controls the MOSFETs to conduct in stages during the 5-millisecond instantaneous current surge stage when the starter motor is activated. The power conversion module includes a 24V / 28V conversion unit and a 12V conversion unit. The former adopts a synchronous four-switch Buck-Boost topology, corresponding to five 24V and five 28V outputs, with a single-channel current of 5A. The latter adopts a BUCK topology, containing two sets of 12V / 50A and two sets of 12V / 15A modules, corresponding to fifteen servo motor 12V outputs, fifteen 12V circuit outputs, and power supply for the engine ECU and navigation lights. The multi-channel load switch module is an all-solid-state structure with protection cut-off, with a total of forty-four outputs, and adopts a high power density metal substrate and flexible conductive busbar; The control unit communicates with each module and receives flight control signals based on the CAN bus to achieve power supply status monitoring and control. The output interface module is adapted to UAV flight controllers, engine ECUs, navigation lights, electro-optical pods, and fire control reserved interfaces through connectors of different specifications.

[0006] Furthermore, the 7S lithium battery has a voltage of 25.9 volts to 29.4 volts, a capacity of 40,000 mAh, and a discharge rate of 25C; the servo motor has a normal output current of 1.6 amps at 12 volts and a short-term overload current of 6 amps for 10 seconds; the 12 volt circuit output current is 5 amps; the engine ECU power supply current is 12.5 amps; and the navigation light power supply current is 10 amps.

[0007] Furthermore, the control unit has a built-in load priority allocation module. The primary load is the flight control and engine ECU, the secondary load is the electro-optical pod and navigation lights, and the tertiary load is the fire control reserved interface and extended load. The multi-channel load switch module has a built-in fault detection unit. When a short circuit or overcurrent occurs in a certain channel, the control unit cuts off the fault channel within 0.1 milliseconds and dynamically allocates the redundant power to the primary and secondary loads.

[0008] Furthermore, the 24V / 28V conversion unit shares a nanocrystalline alloy integrated magnetic core with the 12V conversion unit, forming multiple independent magnetic channels through magnetic circuit coupling. The control unit independently controls the magnetic resistance of each magnetic channel through a dynamic magnetic resistance adjustment circuit, achieving precise control of multiple voltages with a voltage accuracy of ±0.1V and a power density that is more than 30% higher than that of traditional distributed power supply systems.

[0009] Furthermore, the MOSFETs in the pre-charge / discharge buffer matrix have a withstand voltage of no less than 50 volts and a conduction current of no less than 100 amps. The RC buffer network has a resistance of 1 to 5 ohms and a capacitance of 100 to 500 microfarads. The buffer control unit is an FPGA chip, which controls the MOSFETs to conduct in stages at 0.8 millisecond intervals through a Verilog program. The total conduction time does not exceed 4 milliseconds, the instantaneous current peak is reduced by 40%, and the lithium battery voltage fluctuation does not exceed ±0.5 volts.

[0010] Furthermore, the metal substrate of the multi-load switch module is an aluminum nitride ceramic substrate, with the bottom surface encapsulated with thermally conductive adhesive having a thermal conductivity of 2.0 W / m Kelvin, and the top surface is provided with heat dissipation fins that correspond to the aerodynamic air duct of the UAV arm; the encapsulation shell has a built-in silicone elastic damping layer with a Shore hardness of 50, and the power supply fluctuation does not exceed ±0.5% under a vibration environment of 10 to 2000 Hz.

[0011] Furthermore, the 24V / 28V conversion unit is equipped with a 30A-level EMC filter circuit, and the 12V conversion unit is equipped with a 60A-level EMC filter circuit. The filter circuit adopts a three-dimensional layout of common-mode choke and differential-mode capacitor, and the common ground node is equipped with an integrated differential and common-mode filter unit. The output ripple voltage does not exceed 15mV, and the radiated interference value does not exceed 30dB / µV per meter.

[0012] Furthermore, the control unit adopts a dual-core architecture of ARM and FPGA, and communicates via SPI bus; it interacts bidirectionally with the flight controller via CAN bus, and adjusts the output power ratio 50 to 100 milliseconds in advance. During the climb phase, it prioritizes power supply to the engine ECU, optimizes power supply to the optoelectronic pod during the hovering phase, and reduces the power of non-critical loads during the braking phase.

[0013] Furthermore, the input module has a built-in voltage sampling chip. When the lithium battery voltage is lower than 25.9 volts, the control unit sends a warning signal to the flight controller to reduce the power supply to the three-level loads and prioritize the stable power supply to the first and second-level loads.

[0014] Furthermore, the output interface module includes 10-pin, 30-pin, and 2-pin connectors, which are adapted to loads with a single-channel current not exceeding 6 amps, 5 amps, and 12.5 amps, respectively. Each interface has a built-in independent overvoltage / overcurrent protection unit and a reverse connection protection diode. The control unit has a built-in power supply health assessment module that monitors the MOSFET on-state voltage drop, switching losses, and contact resistance. When the health index is below 60 points, the load distribution ratio is adjusted to extend the overall system lifespan by more than 60%.

[0015] Compared with existing technologies, this high-power-density UAV multi-channel integrated power supply system has the following advantages: I. This invention employs a three-group parallel N-channel enhancement-mode MOSFET staged conduction design in a pre-charge / discharge buffer matrix, combined with an RC buffer network and FPGA chip timing control, to precisely handle the 250A instantaneous current surge during start-up of the heuristic motor within 5 milliseconds. The MOSFETs are turned on gradually at fixed intervals, effectively smoothing the current peak, preventing a sudden drop in lithium battery voltage, and ensuring stable operation of power devices. Simultaneously, the dual-channel isolation design and wide voltage adaptability of the input module accommodate different power supply scenarios. The multi-topology structure and precise current distribution of the power conversion module meet the diverse needs of various load types, such as servos, engine ECUs, and optoelectronic pods, ensuring continuous and stable power supply to the 44 output channels, adapting to the power supply requirements of UAVs under complex flight conditions.

[0016] II. This invention achieves high integration and efficient collaboration of multiple power supplies through a magnetic component co-integration topology and a dynamic load priority allocation mechanism. The shared design of the nanocrystalline alloy integrated magnetic core, combined with a dynamic magnetoresistive adjustment circuit, reduces the space occupied by independent magnetic components, making the system structure more compact and adaptable to the lightweight design requirements of UAVs. The load priority allocation is linked with the fault detection unit, which quickly cuts off the fault circuit in the event of a short circuit or overcurrent, directing redundant power to the core load and avoiding power interruption of critical systems. In addition, the heat dissipation structure adapted to the aluminum nitride ceramic substrate and aerodynamic air duct, the vibration-resistant design of the silicone elastic damping layer, and the differential and common-mode integrated filter unit enable the system to maintain stable performance in a wide temperature range and high vibration environment, meet electromagnetic compatibility standards, and extend the overall service life.

[0017] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0019] Figure 1 This is a schematic diagram of the overall system structure and signal flow. Figure 2 Workflow diagram for the pre-charge / discharge buffer matrix; Figure 3 This is a flowchart of load priority and fault handling. Detailed Implementation

[0020] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0021] Example 1: This embodiment demonstrates the practical application of a high-power-density UAV multi-channel integrated power supply system in regular flight. The system connects to a 20 to 32 volt DC power supply and provides continuous and stable power to 44 different loads through designs such as dual-channel redundant power supply, hierarchical conduction buffer, multi-topology power conversion, and intelligent scheduling and distribution. Throughout the flight, the power supply voltage accuracy of core equipment such as flight control and engine ECU is controlled within ±0.1 volts, the output ripple does not exceed 15 millivolts, and the electromagnetic radiation complies with relevant specifications. It is fully adapted to the power supply needs of UAVs for daily tasks such as cruise and hovering, and exhibits good stability and adaptability.

[0022] The overall system structure and signal flow diagram are shown below. Figure 1 As shown, the specific implementation process is as follows: After the system powers on, a full initialization is completed. The ARM chip and FPGA chip in the core control section establish high-speed communication via the SPI bus, maintaining a communication rate of 10 megabits per second to ensure timely command and data transmission. The ARM chip completes its initial interaction with the UAV flight controller via the CAN bus, sending a system ready signal and acquiring the current flight mission, activated load list, and initial attitude data to provide a reference for subsequent power allocation. The FPGA chip simultaneously loads the timing control program for the pre-charge and discharge buffer matrix and configures the PWM signal parameters of the power conversion module, including the 20 kHz switching frequency and initial duty cycle, to prepare for power conversion.

[0023] During the initialization phase, the input module simultaneously initiates dual-power supply detection and switching. The main input interface connects to the 20-32V DC power supply circuit of the helical motor, which is the main power source for the drone, capable of stably outputting 62.5A to 100A current, perfectly matching the system's 2kW power requirement. The backup input interface connects to a 7S lithium battery, with a voltage range of 25.9V to 29.4V, a capacity of 40,000mAh, and a discharge rate of 25C, which can quickly fill the gap in case of a main power supply failure. Electrical isolation between the two inputs is achieved using Schottky diodes. These diodes have low forward voltage drop and fast response speed, effectively preventing circulating current interference between the two power supplies, ensuring that only one power supply is the main power supply at any given time, while the other is in standby mode. The structural design ensures uninterrupted power supply.

[0024] like Figure 2 As shown, the pre-charge / discharge buffer matrix does not require surge protection activation under normal operating conditions; its main function is to provide a low-impedance power transmission path. This matrix consists of three parallel N-channel enhancement-mode MOSFETs, each with a withstand voltage of at least 50 volts and a conduction current of at least 100 amps. This specification is chosen to match the system's maximum input current and prevent single-transistor damage due to overload. Each MOSFET is connected in series with an independent RC buffer branch. The resistance of the RC buffer network is between 1 and 5 ohms, and the capacitance is between 100 and 500 microfarads. Under normal conduction conditions, the RC branch does not participate in current limiting; it only absorbs instantaneous voltage spikes in the circuit, providing protection. The FPGA chip of the buffer control unit outputs a continuous conduction signal, controlling all three MOSFETs to be fully conducting simultaneously. At this time, the overall impedance of the matrix is ​​extremely low, allowing the power transmitted from the input module to be efficiently delivered to the power conversion module without causing unnecessary energy loss.

[0025] After receiving electrical energy, the power conversion module initiates multi-topology conversion according to load requirements. The 24V / 28V conversion unit adopts a synchronous four-switch Buck-Boost topology, which enables bidirectional buck-boost conversion and can adapt to wide input voltage fluctuations from 20 to 32V, ensuring stable output voltage. When the flight controller issues a hover command, the unit converts the input voltage to a stable 24V output, powering the electro-optical pod through five 24V channels. The electro-optical pod has an average power of 200W and a peak power of 500W, and the single-channel 5A output current is sufficient to meet its power requirements. If fire control equipment needs to be activated, the unit switches to 28V output mode, powering the fire control reserved interface through five 28V channels. The 12V conversion unit adopts a mature BUCK topology, consisting of two 12V / 50A modules and two 12V / 15A modules. The two 12V / 50A modules are responsible for powering fifteen servo motors and fifteen 12V circuits. The normal operating current of the servo motors is 1.6A, and they support a short-term overload of 6A for 10 seconds. The single-circuit current of the 12V circuits is 5A. The output capacity of the two modules fully covers the load requirements. The two 12V / 15A modules power the engine ECU and the navigation lights, respectively. The engine ECU operates at a current of 12.5A, and the navigation lights operate at a current of 10A. The module output has sufficient margin. The 24V / 28V conversion unit shares a nanocrystalline alloy integrated magnetic core with the 12V conversion unit. This magnetic core has high permeability and low loss. Through magnetic circuit coupling, multiple independent magnetic channels are formed. Each channel corresponds to a magnetic coupling circuit for one output voltage. The control part independently changes the magnetic resistance of each magnetic channel through a dynamic reluctance adjustment circuit, thereby precisely controlling the output voltage of each channel and avoiding magnetic interference between different voltage levels. This is also the key to the system's high integration.

[0026] As a crucial component in power distribution, the multi-channel load switch module utilizes a high-power-density aluminum nitride ceramic substrate as its mounting medium. This substrate boasts excellent thermal conductivity, enabling rapid heat dissipation during device operation. Flexible conductive busbars are integrated into the substrate surface, replacing traditional cable connections. These flexible busbars offer superior bending performance and low contact resistance, reducing the risk of solder joint detachment under vibration and simultaneously lowering the overall system size and weight. The module's built-in fault detection unit acquires current signals through precision sampling resistors connected in series in each channel, working in conjunction with a voltage comparator to monitor channel voltage in real time, achieving a detection accuracy of ±0.5%. Figure 3 As shown, under normal operating conditions without faults, the fault detection unit continuously outputs a normal signal, and the multi-channel load switch module keeps all channels conducting, smoothly delivering the electrical energy converted by the power conversion module to the output interface module.

[0027] The output interface module is configured with three different connector specifications based on load current levels and connection requirements. The 10-pin connector is specifically designed for 15-channel 12V servo loads, with a single-channel current carrying capacity of no more than 6A, meeting the current requirements for normal servo operation and short-term overload. The 30-pin connector is compatible with 15-channel 12V circuits and five-channel 24V general loads, with a single-channel current carrying capacity of no more than 5A, suitable for small to medium power loads. The 2-pin connector is used for high-current loads such as engine ECUs, navigation lights, and optoelectronic pods, with a current carrying capacity of no more than 12.5A, ensuring stable contact during high-current transmission. Each interface has a built-in independent overvoltage / overcurrent protection unit and a reverse connection protection diode. The overvoltage protection unit automatically cuts off power when the voltage exceeds the rated value by 10%, the overcurrent protection unit activates protection when the current exceeds the rated value by 20%, and the reverse connection protection diode prevents short circuit damage caused by reversed load polarity. Multiple protections form a closed loop, ensuring dual safety for both the load and the system.

[0028] During stable system operation, the control unit continuously monitors and dynamically adjusts its status. The ARM chip receives real-time voltage and current data from 44 channels of the multi-load switch module, and dynamically optimizes the output power allocation of the power conversion module based on flight attitude changes transmitted by the flight control system: when the UAV enters the climb phase, it prioritizes allocating 12V 12.5A rated power to the engine ECU to ensure sufficient power supply to the power system; when entering the hovering phase, it focuses on optimizing the power supply parameters of the electro-optical pod, reducing output ripple by fine-tuning the PWM duty cycle to improve the stability of the electro-optical pod; when entering the braking phase, it appropriately reduces the power allocation of the third-level loads such as the fire control reserved interface to reduce energy consumption. At the same time, the control unit's built-in power supply health assessment module continuously monitors the on-state voltage drop and switching losses of the MOSFETs in the power conversion module, as well as the contact resistance of the multi-load switch module, to establish a health status model. When a slight abnormality is detected in a device parameter, the load allocation ratio is adjusted in a timely manner, transferring high-power loads to healthy devices to prevent further aging of abnormal devices and extend the overall service life of the system.

[0029] This embodiment verifies the collaborative working capability and stable performance of the various modules of the system through practical application under normal UAV flight conditions. The dual-redundancy design of the input module ensures power supply continuity from the source, the low-impedance conduction of the pre-charge and discharge buffer matrix enables efficient power transmission, the multi-topology and integrated magnetic core design of the power conversion module completes precise power conversion, the intelligent scheduling of the control section optimizes power distribution, and the multi-load switch module and output interface module construct a safe and reliable power transmission channel.

[0030] Example 2: This embodiment simulates the operation of a high-power-density UAV multi-channel integrated power supply system under extreme conditions. The focus of the test is on the system's performance under conditions including instantaneous high-current surges during start-up of the heuristic motor, load short-circuit faults, and high-vibration environments ranging from -40°C to 65°C and 10 to 2000 Hz. Through graded conduction buffering to withstand instantaneous high currents, load priority allocation and fault detection for rapid self-healing, and special structural design and electromagnetic compatibility optimization to ensure stable operation in extreme environments, the core load power supply remains uninterrupted throughout the process, and fluctuations in key parameters are controlled within permissible ranges, meeting the stringent power supply requirements of complex UAV mission scenarios.

[0031] The specific implementation process is as follows: After system startup, the UAV flight controller issues a start command for the heuristic motor, officially commencing the extreme condition test. The start-up phase of the heuristic motor generates a transient current surge of 250 amps, lasting 5 milliseconds. If this large current were to directly enter subsequent modules, it could easily cause power device burnout and a sudden drop in lithium battery voltage. Therefore, the pre-charge / discharge buffer matrix immediately activates its surge protection mechanism. The FPGA chip of the buffer control unit, according to a preset Verilog timing control program, initiates the graded conduction logic of three sets of MOSFETs: the first set of MOSFETs turns on at 0 milliseconds, at which point only a single channel carries current, and the current-limiting effect of the RC buffer network initially weakens the current peak; the second set of MOSFETs turns on at 0.8 milliseconds, with parallel current sharing across two channels, further reducing the current pressure on a single channel; the third set of MOSFETs turns on at 1.6 milliseconds, with all three channels fully open, achieving maximum current sharing. The capacitors in the RC buffer network rapidly charge and discharge, helping to smooth the current rise edge and avoid spikes caused by sudden current changes, while the resistors dissipate some of the surge energy through moderate heat generation. The entire graded conduction process takes no more than 4 milliseconds, fully covering the 5-millisecond instantaneous impact period, ultimately reducing the instantaneous current peak by 40% and controlling the lithium battery voltage fluctuation within ±0.5 volts, effectively protecting the safety of subsequent power conversion modules and power devices.

[0032] After the instantaneous current surge, the system entered a stable operating phase, and then triggered a load fault simulation test: a 12V servo load experienced a short circuit due to insulation damage. The fault detection unit built into the multi-channel load switch module quickly captured the current surge in this channel through a sampling resistor, and fed back the overcurrent fault signal to the ARM chip in the control section within 0.05 milliseconds. The ARM chip immediately invoked the preset rules of the load priority allocation module to confirm that the servo load corresponding to the short-circuited channel was a level 3 load, while the flight controller and engine ECU were level 1 loads, and the electro-optical pod and navigation lights were level 2 loads. The core principle was to ensure continuous power supply to level 1 and level 2 loads. The ARM chip sent a cut-off command to the multi-channel load switch module within 0.1 milliseconds. The all-solid-state MOSFET switch inside the module quickly shut down the faulty channel to prevent the fault from spreading; at the same time, it calculated the redundant power of the faulty channel and allocated the redundant power to the channels where the flight controller and engine ECU were located by dynamically adjusting the output power ratio of the power conversion module, ensuring that the power supply voltage fluctuation of the level 1 load did not exceed ±0.3 volts, and had no impact on the UAV's flight attitude control.

[0033] After troubleshooting, the system entered a testing phase involving a wide temperature range and high vibration. The ambient temperature gradually dropped to the -40℃ low-temperature limit, while the drone fuselage generated random vibrations ranging from 10 to 2000 Hz. The special structural design of the multi-load switch module played a crucial role in this scenario: its encapsulation shell incorporates a silicone elastic damping layer with a Shore hardness of 50. This damping layer has excellent elastic deformation capability, effectively absorbing vibration energy and reducing the impact of vibration on the substrate and component solder joints, keeping power supply fluctuations within ±0.5%. The metal substrate is made of aluminum nitride ceramic material, with the bottom surface encapsulated with thermally conductive adhesive with a thermal conductivity of 2.0 W / m Kelvin. The thermally conductive adhesive adheres tightly to the substrate and shell, rapidly conducting the operating heat of the components. The heat dissipation fins on the top surface are precisely aligned with the aerodynamic air ducts of the drone arm, and the airflow generated during flight forms forced convection cooling. Even in the -40℃ low-temperature environment, it can prevent the performance degradation of components due to excessively low temperatures, while also preventing condensation from causing short circuits.

[0034] The power conversion module maintains high-efficiency power conversion even in extreme environments. The 24V / 28V conversion unit shares a nanocrystalline alloy integrated magnetic core with the 12V conversion unit, maintaining stable permeability across a wide temperature range and preventing magnetic performance fluctuations due to temperature changes. The control section uses a dynamic reluctance adjustment circuit to monitor the reluctance changes of each magnetic channel in real time. By fine-tuning the resistance of the adjustable inductor, the reluctance of each magnetic channel is independently controlled, ensuring accurate and stable output voltages for 24V, 28V, and 12V channels, with voltage accuracy consistently maintained within ±0.1V. Meanwhile, the EMC filtering circuit of the power conversion module plays a full role: the 24V / 28V conversion unit is equipped with a 30A-level EMC filtering circuit, and the 12V conversion unit is equipped with a 60A-level EMC filtering circuit. Both adopt a three-dimensional layout of common-mode chokes and differential-mode capacitors. The common-mode chokes suppress common-mode interference in the circuit, and the differential-mode capacitors absorb differential-mode noise. Together with the differential and common-mode integrated filtering unit set in the forty-four-channel output common ground node, a comprehensive electromagnetic interference suppression network is formed, which ultimately controls the system radiated interference value to within 30 dB microvolts per meter, so as not to interfere with other electronic devices of the UAV.

[0035] The control unit continuously enhances monitoring and scheduling in extreme environments. It acquires environmental monitoring data transmitted from the flight controller in real time via the CAN bus, including current ambient temperature, vibration frequency, and changes in UAV flight attitude. It adjusts the output parameters of the power conversion module 50 to 100 milliseconds in advance: in low-temperature environments, it appropriately increases the PWM duty cycle to compensate for voltage loss due to reduced battery discharge capacity; in high-vibration environments, it increases the sampling frequency of the fault detection unit to ensure timely detection of potential faults. The voltage sampling chip built into the input module continuously monitors the 7S lithium battery voltage. When it detects that the lithium battery voltage has dropped to 25.8 volts due to low-temperature discharge characteristics, below the undervoltage threshold of 25.9 volts, the control unit immediately sends an undervoltage warning signal to the flight controller. Simultaneously, it automatically reduces the power supply to tertiary loads such as the fire control reserved interface, prioritizing the allocation of the saved power to primary loads such as the flight controller and engine ECU, as well as secondary loads such as the optoelectronic pod and navigation lights, ensuring that the power supply to core equipment is not affected. In addition, the power supply health assessment module in the control section increases the monitoring frequency under extreme environments, collecting data on the on-state voltage drop, switching losses, and contact resistance of the MOSFETs in the power conversion module every 100 milliseconds. When the on-state voltage drop of a certain MOSFET is detected to rise from the normal range of 0.1 to 0.3 volts to 0.45 volts, it is determined that the device has a slight aging trend. The load distribution ratio is then adjusted to transfer high-power loads to other healthy power supplies, reducing the load on aging power supplies by 50% and preventing them from being completely damaged under extreme environmental stress.

[0036] This embodiment verifies the core performance advantages of the system by simulating extreme conditions such as instantaneous high current surges in the starter motor, load short-circuit faults, and high vibrations over a wide temperature range. The graded conduction design of the pre-charge and discharge buffer matrix successfully withstands a 250-amp instantaneous current surge, solving the problem of insufficient surge resistance in traditional systems; the load priority allocation and fault detection unit enables rapid fault self-healing, ensuring uninterrupted power supply to the core load; and the special structural design and electromagnetic compatibility optimization ensure stable operation of the system in extreme environments.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-power-density UAV multi-channel integrated power supply system, characterized in that, The system includes an input module, a pre-charge / discharge buffer matrix, a power conversion module, a multi-channel load switch module, a control unit, and an output interface module. The input module accepts 20 to 32 volt DC input, corresponding to a 2 kW power requirement, with an input current of 62.5 amps to 100 amps. It includes a main input interface connected to the starter motor power supply circuit and a 7S lithium battery backup input interface, with dual-channel isolation via Schottky diodes. The pre-charge and discharge buffer matrix is ​​connected in series between the input module and the power conversion module. It includes an array of three sets of parallel N-channel enhancement-mode MOSFETs, an RC buffer network, and a buffer control unit. Each set of MOSFETs is connected in series with an independent RC branch. The buffer control unit controls the MOSFETs to conduct in stages during the 5-millisecond instantaneous current surge stage when the starter motor is activated. The power conversion module includes a 24V / 28V conversion unit and a 12V conversion unit. The former adopts a synchronous four-switch Buck-Boost topology, corresponding to five 24V and five 28V outputs, with a single-channel current of 5A. The latter adopts a BUCK topology, containing two sets of 12V / 50A and two sets of 12V / 15A modules, corresponding to fifteen servo motor 12V outputs, fifteen 12V circuit outputs, and power supply for the engine ECU and navigation lights. The multi-channel load switch module is an all-solid-state structure with protection cut-off, with a total of forty-four outputs, and adopts a high power density metal substrate and flexible conductive busbar; The control unit communicates with each module and receives flight control signals based on the CAN bus to achieve power supply status monitoring and control. The output interface module is adapted to UAV flight controllers, engine ECUs, navigation lights, electro-optical pods, and fire control reserved interfaces through connectors of different specifications.

2. The high power density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The 7S lithium battery has a voltage of 25.9V to 29.4V, a capacity of 40000mAh, and a discharge rate of 25C; the servo motor has a normal output current of 1.6A at 12V and a short-term overload current of 6A for 10 seconds; the 12V circuit output current is 5A; the engine ECU power supply current is 12.5A; and the navigation light power supply current is 10A.

3. The high power density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The control unit has a built-in load priority allocation module. The first-level load is the flight control and engine ECU, the second-level load is the electro-optical pod and navigation lights, and the third-level load is the fire control reserved interface and expansion load. The multi-channel load switch module has a built-in fault detection unit. When a short circuit or overcurrent occurs in a certain channel, the control unit cuts off the fault channel within 0.1 milliseconds and dynamically allocates the redundant power to the first-level and second-level loads.

4. The high power density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The 24V / 28V conversion unit and the 12V conversion unit share a nanocrystalline alloy integrated magnetic core, forming multiple independent magnetic channels through magnetic circuit coupling. The control unit independently controls the magnetic resistance of each magnetic channel through a dynamic magnetic resistance adjustment circuit, achieving precise control of multiple voltages with a voltage accuracy of ±0.1V.

5. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The MOSFETs in the pre-charge / discharge buffer matrix have a withstand voltage of no less than 50 volts and a conduction current of no less than 100 amps. The RC buffer network has a resistance of 1 to 5 ohms and a capacitance of 100 to 500 microfarads. The buffer control unit is an FPGA chip, which controls the MOSFETs to conduct in stages at 0.8 millisecond intervals through a Verilog program. The total conduction time does not exceed 4 milliseconds, the instantaneous current peak is reduced by 40%, and the lithium battery voltage fluctuation does not exceed ±0.5 volts.

6. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The metal substrate of the multi-load switch module is an aluminum nitride ceramic substrate, with the bottom surface encapsulated with thermally conductive adhesive with a thermal conductivity of 2.0 W / m Kelvin, and the top surface is provided with heat dissipation fins that correspond to the aerodynamic air duct of the UAV arm; the encapsulation shell has a built-in silicone elastic damping layer with a Shore hardness of 50, and the power supply fluctuation does not exceed ±0.5% under a vibration environment of 10 to 2000 Hz.

7. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The 24V / 28V conversion unit is equipped with a 30A-level EMC filter circuit, and the 12V conversion unit is equipped with a 60A-level EMC filter circuit. The filter circuit adopts a three-dimensional layout of common-mode choke and differential-mode capacitor, and the common ground node is equipped with an integrated differential and common-mode filter unit. The output ripple voltage does not exceed 15mV, and the radiated interference value does not exceed 30dB / µV per meter.

8. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The control unit adopts a dual-core architecture of ARM and FPGA and communicates via SPI bus. It interacts bidirectionally with the flight control via CAN bus and adjusts the output power ratio 50 to 100 milliseconds in advance. During the climb phase, it prioritizes power supply to the engine ECU, optimizes power supply to the optoelectronic pod during the hovering phase, and reduces power to non-critical loads during the braking phase.

9. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The input module has a built-in voltage sampling chip. When the lithium battery voltage is lower than 25.9 volts, the control unit sends a warning signal to the flight controller to reduce the power supply of the three-level loads and prioritize the stable power supply of the first and second-level loads.

10. A high-power-density UAV multi-channel integrated power supply system according to claim 1, characterized in that, The output interface module includes 10-pin, 30-pin, and 2-pin connectors, which are adapted to loads with a single-channel current not exceeding 6A, 5A, and 12.5A, respectively. Each interface has a built-in independent overvoltage / overcurrent protection unit and a reverse connection protection diode. The control unit has a built-in power supply health assessment module that monitors the MOSFET on-state voltage drop, switching loss, and contact resistance. When the health index is below 60 points, the load distribution ratio is adjusted.

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