Enhanced redundancy in hybrid voltage low voltage systems

Abstract

The subject technology provides a power conversion architecture having a first power converter configured to receive power from a first power source and supply power to a first voltage domain, and a second power converter configured to receive power from a second power source and supply power to a second voltage domain. Each converter delivers power to a respective power path that includes both a primary load and a redundant load. A third power converter is coupled between the first voltage domain and the second voltage domain and enables bidirectional power transfer in response to a fault condition. This configuration supports fault-tolerant operation in safety-critical automotive systems, including line control braking, line control steering, and autonomous driving systems, where uninterrupted functionality can be beneficial to maintain operational safety. By utilizing only three DC-DC converters, the subject technology reduces bill of materials cost, weight, part count, and thermal management overhead. The architecture enables a hybrid voltage system while maintaining compatibility across different vehicle platforms.

Description

[0001] introduction

[0002] This application relates to power management systems for electric vehicles, such as enhanced redundancy in hybrid voltage low-voltage systems. Summary of the Invention

[0003] This subject matter technology provides a power conversion system comprising a first power converter supplying power to a first voltage domain, a second power converter supplying power to a different second voltage domain, and a third power converter configured to transfer power between the two domains based on fault conditions. Each voltage domain includes a primary load and a redundant load. This configuration supports fault-tolerant operation of automotive systems such as brake-by-wire, steering-by-wire, and autonomous driving platforms, where maintaining functionality during failures is beneficial. By using three DC-DC converters instead of four, this subject matter technology reduces cost, weight, component count, and thermal management requirements while maintaining redundancy. This architecture supports mixed voltage systems (e.g., 12V and 48V), thereby enabling reduced wiring complexity and adaptability across multiple vehicle platforms without relying on traditional mechanical subsystems. Attached Figure Description

[0004] Certain features of the present subject matter are set forth in the appended claims. However, for purposes of explanation, several embodiments of the present subject matter are illustrated in the following figures.

[0005] Figure 1A A schematic top view illustrating an example embodiment of a vehicle based on one or more specific embodiments is shown.

[0006] Figure 1B A schematic side view illustrating an example embodiment of a vehicle based on one or more specific embodiments is shown.

[0007] Figure 2 An exemplary block diagram of a power management system according to one or more specific implementations is illustrated, the power management system including a plurality of power converters.

[0008] Figure 3 An exemplary block diagram of a power management system according to one or more specific implementations is illustrated, the power management system including a plurality of power converters with enhanced redundancy.

[0009] Figure 4 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a first fault condition in a power management system, which includes multiple power converters with enhanced redundancy.

[0010] Figure 5Conceptually exemplified according to one or more specific implementations Figure 3 An example of a second fault condition in a power management system, which includes multiple power converters with enhanced redundancy.

[0011] Figure 6 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a third fault condition in a power management system that includes multiple power converters with enhanced redundancy.

[0012] Figure 7 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a fourth fault condition in a power management system, which includes multiple power converters with enhanced redundancy.

[0013] Figure 8 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a fifth fault condition in a power management system that includes multiple power converters with enhanced redundancy.

[0014] Figure 9 Conceptually exemplified according to one or more specific implementations Figure 3 An example of load balancing functionality in a power management system, which includes multiple power converters with enhanced redundancy.

[0015] Figure 10 Conceptually exemplified according to one or more specific implementations Figure 3 An example of active balancing functionality in a power management system, which includes multiple power converters with enhanced redundancy.

[0016] Figure 11 It is a flowchart of exemplary operations that can be performed according to one or more specific implementations for enhanced redundancy in mixed-voltage low-voltage systems. Detailed Implementation

[0017] The detailed description set forth below is intended to describe various configurations of the subject matter and is not intended to represent the only configuration in which the subject matter can be practiced. The accompanying drawings are incorporated herein and form part of the detailed description. The detailed description includes specific details in order to provide a thorough understanding of the subject matter. However, those skilled in the art will clearly understand that the subject matter is not limited to the specific details set forth herein and can be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the concepts of the subject matter.

[0018] In the automotive industry, brake-by-wire (BBW), steer-by-wire (SBW), and automated driving (SD) systems exhibit safety-critical behavior, where functional availability helps mitigate safety risks. Shutting down these systems in response to failures may be inconsistent with safety objectives. The power supplies for these units can benefit from high robustness and may include redundancy to prevent the loss of safety-critical functions due to a single failure. This redundancy may increase costs due to the involvement of additional components. Additionally, the power consumption characteristics of these systems may benefit from higher operating voltages (e.g., 48V) to reduce wiring harness requirements by lowering current consumption; however, most other automotive electronics operate at 12V.

[0019] In hybrid low-voltage (LV) systems where redundancy can contribute to availability safety, a configuration utilizing four power converters (e.g., DC-DC converters) can be implemented to achieve a beneficial level of redundancy. In one or more specific implementations, the number of DC-DC converters in the power conversion stage can be reduced to three instead of four, without relying on alternative power supplies, while maintaining availability safety beneficial to BBW, SBW, and SD systems.

[0020] Implementations of the technologies described in this paper offer competitive advantages, including lower bill of materials (BOM) costs, reduced weight, fewer components requiring encapsulation, and lower thermal management requirements due to the reduced component count (e.g., the number of DC-DC converters is reduced from four to three). BBW, SBW, and SD systems can facilitate more adaptive platform configurations by eliminating constraints associated with traditional steering columns, brake pedals, and power assist systems for left-hand and right-hand driving variations. These systems can be implemented on multiple platforms with fewer packaging limitations. A high level of autonomy means that features of power conversion redundancy can be benefited from, and the reduction in power conversion redundancy can help lower the cost of the architecture supporting these functionalities.

[0021] Figure 1A An example top view of a vehicle 100 is illustrated. As further described herein, the vehicle 100 may include one or more ECUs (e.g., ECU 150) in the front portion 130 of the vehicle 100. An ECU (e.g., ECU 150) is an embedded system that controls one or more of the electrical systems or subsystems in the vehicle 100.

[0022] Figure 1BAn example side view of a vehicle 100 is illustrated. As shown, the vehicle 100 may include one or more battery packs, such as a high-voltage (HV) battery pack 110 (e.g., 450V), which may be located near the central body portion 135 of the vehicle 100. The HV battery pack 110 may be coupled to one or more electrical systems of the vehicle 100 to supply power to the electrical systems. In one or more embodiments, ECUs 150 may be communicatively connected to each other or have power distributed to each other, and the power or other operation of the electronic components of the vehicle 100 may be functionally redundant.

[0023] In one or more embodiments, vehicle 100 may be an electric vehicle having one or more electric motors that use electricity from HV battery pack 110 to drive the wheels 102 of vehicle 100. In one or more embodiments, vehicle 100 may also include or alternatively include one or more chemically powered engines, such as gas-powered engines or fuel cell-powered motors. For example, electric vehicles may be fully electric or partially electric (e.g., hybrid or plug-in hybrid). In various embodiments, vehicle 100 may be a fully automated vehicle capable of operating on roads without a human operator or driver, a partially autonomous vehicle capable of operating on some roads without a human operator or driver or capable of operating on roads under the supervision of a human operator, a driverless vehicle capable of operating on roads or other paths without any human occupants, or a human-operated (non-automatic) vehicle configured for human operation.

[0024] exist Figure 1B In the example, vehicle 100 may be implemented as a truck (e.g., a pickup truck) with battery pack 110. As shown, HV battery pack 110 may include one or more battery modules 115, which may include one or more battery cells 120. However, this is merely illustrative, and in other specific implementations, HV battery pack 110 may be provided without any battery modules 115 (e.g., in a cell-to-pack configuration).

[0025] like Figure 1BAs shown, vehicle 100 may include a support structure, such as chassis 125 (e.g., frame, internal frame, or other support structure). Chassis 125 may support various components of vehicle 100. As shown, in some embodiments, chassis 125 may span the front portion 130 (e.g., hood or cover portion), central body portion 135, and rear portion 140 (e.g., luggage compartment, payload, or trunk portion) of vehicle 100. In one or more embodiments, HV battery pack 110 may be mounted on chassis 125 (e.g., within one or more of the front portion 130, central body portion 135, or rear portion 140). In one or more other embodiments, the HV battery pack 110 may include one or more buses (e.g., one or more current collector elements) or be electrically coupled to the one or more buses, wherein the one or more buses may include conductive material to connect or otherwise electrically couple the battery module 115 or battery cell 120 to other electrical components of the vehicle 100 to provide power to various systems or components of the vehicle 100.

[0026] In one or more specific embodiments, vehicle 100 may be implemented as another type of electric truck, electric delivery vehicle, electric motor vehicle, electric car, electric motorcycle, electric scooter, electric bus, electric passenger or commercial truck, hybrid vehicle or other vehicle, such as sea or air transport, aircraft, helicopter, submarine, ship or drone, or any other mobile device having a battery pack 110 (e.g., which powers the propulsion or drive components of the mobile device).

[0027] In one or more embodiments, vehicle 100 includes a power management system 160 that includes a DC-DC converter for reducing energy from a high-voltage battery pack (e.g., HV battery pack 110) to supply energy to low-voltage subsystems distributed throughout vehicle 100. Among these low-voltage subsystems are components classified as “safety-critical systems.” For applications where the availability of such systems is beneficial to safety, power is supplied via two independent power sources to mitigate the impact of a single point of failure. For example, in the event of a headlight failure, a fault notification alone may not be sufficient, as the system may still need to address operational impacts, particularly in scenarios such as nighttime driving. In one or more embodiments, the electrical architecture is configured to prevent simultaneous failure of two headlights due to a common fault. This approach can become increasingly suitable for higher levels of vehicle autonomy, where driver disengagement from active vehicle control is anticipated. In one or more embodiments, the fault condition may not be manageable solely through driver takeover prompts. In one or more other embodiments, the system may be configured to support the execution of “minimum-risk maneuvering,” which maintains safety-critical operation for a limited duration. This duration can be designed to allow the driver to re-engage or to enable the vehicle 100 to come to a controlled stop.

[0028] The power management system 160 may employ a DC-DC converter as one power source and a low-voltage (LV) battery (e.g., 12V) as a secondary power source, with the two power sources interconnected via an isolating switch for redundancy and fault tolerance. Technical challenges may be associated with the deployment of LV batteries in vehicle systems. In one or more embodiments, LV batteries present challenges related to estimating their internal states, including electrochemical kinetics and thermal characteristics under various load conditions. In one or more other embodiments, the power management system 160 may remove the LV battery as a dedicated energy source and include an architecture incorporating two DC-DC converters. This configuration facilitates improved control of power availability on low-voltage subsystems with equivalent redundancy and fault handling mechanisms. With an architecture having a dual DC-DC converter configuration, the power management system 160 may also include a split-cell battery topology and two LV DC-DC converters (e.g., 12V DC-DC converters).

[0029] Further architectural evolution is driven by the shift towards "brake-by-wire" and "steer-by-wire" systems, which eliminate the mechanical linkage between user input mechanisms (such as the steering wheel or brake pedal) and the actuation components of the vehicle's motion control system. These systems can operate entirely through electronic control and signal transmission. In one or more implementations, redundant supply becomes beneficial because uninterrupted functionality is advantageous for safety in the event of a failure. Given the high current requirements of these subsystems, the power management system 160 can employ a 48V system, which provides a beneficial reduction in conductor cross-sectional area due to the inverse quadratic relationship between current and wire gauge for a given power level. This can lead to reduced wiring harness quality and bill of materials costs.

[0030] Figure 2 An exemplary block diagram of a power management system (e.g., power management system 160) according to one or more embodiments is illustrated, which includes multiple power converters. In one or more embodiments, power management system 160 can support safety-critical features without relying on a 12V battery by employing a configuration in which a separate DC-DC converter is allocated for each voltage domain and each physical battery pack segment. For example, power management system 160 includes a first high-voltage (HV) split battery pack 210 and a second high-voltage (HV) split battery pack 220. The first HV split battery pack 210 is configured to power a first power converter 230 and a second power converter 240. The first power converter 230 is configured to convert received high-voltage power to a 48V output and deliver power to a main 48V bus 280. The second power converter 240 is configured to convert received high-voltage power to a 12V output and deliver power to a main 12V bus 290. The second HV split battery pack 220 is configured to power a third power converter 250 and a fourth power converter 260. The third power converter 250 is configured to convert the received high-voltage power to a 48V output and deliver power to a backup 48V bus 285. The fourth power converter 260 is configured to convert the received high-voltage power to a 12V output and deliver power to a backup 12V bus 295.

[0031] In one or more specific implementations, the number of DC-DC converters in the power conversion stage can be reduced to three instead of four, without relying on alternative power supplies, while maintaining availability safety beneficial to BBW, SBW, and SD systems. For example, the power management system 160 can functionally combine two backup DC-DC converters (e.g., a third power converter 250 and a fourth power converter 260) into a single bidirectional power converter configured to switch between 48 volts and 12 volts in both directions, as referenced. Figure 3This will be discussed in more detail. This configuration can produce functionality equivalent to a dual-converter architecture by maintaining the primary and backup power delivery capabilities of both the 48V and 12V networks. In one or more other embodiments, the architecture may include monitoring and control mechanisms capable of fault detection and reconfiguration. Upon detection of a power delivery fault, the system can redirect energy flow across the domains to maintain operational redundancy across both voltage levels. In one or more other embodiments, such monitoring and control mechanisms may be implemented at least partially on ECU 150.

[0032] Figure 3 An exemplary block diagram of a power management system (e.g., power management system 160) according to one or more specific implementations is illustrated, which includes a plurality of power converters with enhanced redundancy. Power management system 160 is configured with multiple power converters to manage power distribution between different voltage domains. Figure 3 As shown, the power management system 160 includes a first HV split-type battery pack 310 that supplies power to a first power converter 330. In one or more embodiments, the first power converter 330 is configured as a 48V converter that can reduce a high-voltage input to 48V. The 48V output from the first power converter 330 can be supplied to a primary 48V bus 380 and a backup 48V bus 385, wherein power distribution to the backup 48V bus 385 is controlled by an isolating switch 360. When the isolating switch 360 is closed, power is supplied to the backup 48V bus 385.

[0033] The power management system 160 also includes a second HV split-type battery pack 320 that supplies power to the second power converter 340. In one or more embodiments, the second power converter 340 is configured as a 12V converter that can reduce a high-voltage input to 12V. The 12V output from the second power converter 340 can be supplied to a primary 12V bus 390 and a backup 12V bus 395, wherein power distribution to the backup 12V bus 395 is controlled by an isolating switch 370. When the isolating switch 370 is closed, power is supplied to the backup 12V bus 395.

[0034] The power management system 160 also includes a third power converter 350 positioned between the 48V and 12V domains. In one or more embodiments, the third power converter 350 is configured to convert power between these domains in a directional manner. If the isolating switch 370 is open, the third power converter 350 can convert 48V to 12V and supply power to the backup 12V bus 395. Conversely, if the isolating switch 360 is open, the third power converter 350 can convert 12V to 48V and supply power to the backup 48V bus 385. This configuration facilitates flexible power cabling, allowing for continuous power supply to the backup bus as needed. Figure 3As shown, there is no fault condition in the power management system 160, so the switching of the third power converter 350 to supply power between voltage domains may not be required, since each voltage domain can supply power to its primary power path and backup power path.

[0035] In one or more other embodiments, when a fault condition is detected in the power management system 160, the power management system 160 may reconfigure the power paths between voltage domains to maintain the power availability of at least one network in the 12V network and one network in the 48V network, thereby facilitating continuous operation in the low-voltage subsystem with equivalent redundancy and fault handling mechanisms.

[0036] In one or more other embodiments, monitoring functionality may be directly integrated within the third power converter 350. In such an embodiment, the third power converter 350 may monitor the operating status of the first disconnect switch 360 or the second disconnect switch 370, and potentially monitor the output conditions of other power converters within the power management system 160. In this regard, the third power converter 350 may determine appropriate response actions, including whether to activate or adjust its power conversion function.

[0037] In one or more embodiments, disconnect switches (e.g., disconnect switches 360, 370) may represent beneficial functional components within the power management system 160 because they determine the configuration of energy delivery paths in response to system events. The behavior of these disconnect switches may be affected by specific triggered or detected conditions indicating fault scenarios within the power management system 160. In one or more other embodiments, each disconnect switch may be electrically connected to network monitoring circuitry capable of autonomous operation.

[0038] In one or more specific implementations, the disconnecting switch (e.g., disconnecting switches 360, 370) may be configured with a default closed state. This configuration allows power to flow simultaneously to both the main bus and the backup bus in the respective voltage domain under nominal operating conditions. The closed state also facilitates monitoring via at least one node connected to the disconnecting switch, thereby allowing the detection of electrical conditions such as current surges or voltage deviations.

[0039] These disconnect switches (e.g., disconnect switches 360, 370) can transition to an open state under specific conditions, primarily in response to detected faults that may affect system stability or redundancy. In one or more embodiments, the disconnect switches may be interleaved with one or more microcontrollers capable of issuing control commands. While microcontroller-based actuation may introduce a slower response time compared to autonomous switching, it enables conditional override logic. For example, if the microcontroller detects that one side of the disconnect switch is open (e.g., a fault is detected on the disconnect switch 360 side), the microcontroller may issue a command to keep the opposite disconnect switch (e.g., disconnect switch 370) closed to maintain power delivery to the backup bus in the opposite voltage domain. This prevents unnecessary disconnections that would otherwise result in power loss for a particular low-voltage subsystem. In one or more embodiments, one or more microcontrollers may be included in ECU 150. In one or more other embodiments, one or more microcontrollers may be decoupled from ECU 150 and communicatively coupled to ECU 150.

[0040] Disconnect switches (e.g., disconnect switches 360, 370) provide independent, high-speed responses, with actuation times of, for example, approximately 500 microseconds. These disconnect switches may each include fault detection circuitry to continuously monitor current and voltage levels on either side of their separated electrical domains. Upon detecting electrical parameters deviating from predefined specifications, such as excessive current consumption or voltage drop, the disconnect switch may initiate a disconnect state transition to interrupt current flow. This action is designed to locate the fault and prevent its propagation to adjacent power networks. For example, in the event of an unregulated line experiencing a short-to-ground fault, current can be diverted from the main bus through the faulty line. This can result in excessive current consumption and voltage sags across both affected buses, potentially leading to functional loss in both voltage domains. The disconnect switches can identify the resulting current surges or voltage anomalies and actuate to disconnect, thereby maintaining the operational integrity of the unaffected or “healthy” side of the power management system 160.

[0041] In addition to isolating switches, the power management system 160 may also include protective switches, such as smart fuses or electronic fuses, placed between the power converter output and each load. For example, critical automotive systems such as steering or braking may be connected individually via additional switches providing local protection. If a fault, such as a short circuit, occurs in any of these subsystems, the corresponding protective switch can switch to the open state, thereby facilitating the preservation of power for other subsystems and minimizing the impact of the fault. These protective switches may work in conjunction with isolating switches to facilitate local isolation of faults, thereby preventing fault propagation and impact on the entire power management system 160.

[0042] Figure 4Conceptually exemplified according to one or more specific implementations Figure 3 An example of a first fault condition in a power management system 160, which includes multiple power converters with enhanced redundancy. For example... Figure 4 As shown, a failure in the second power converter 340 could result in complete power loss across all 12V subsystems (e.g., primary 12V bus 390 and backup 12V bus 395) if no corrective action is taken. To mitigate this, the power management system 160 can initiate a response in which the isolating switch 370 switches to the open state. This action enables the third power converter 350 to perform a voltage buck operation from the 48V domain to the 12V domain.

[0043] In this configuration, the 12V subsystem may no longer be powered by the second power converter 340, but instead receive power routed from the 48V domain via the third power converter 350. This reconfiguration may result in losses on the primary 12V bus 390, but the backup 12V bus 395 becomes active, thus maintaining the availability of 12V power to the subsystems in the 12V domain. In one or more embodiments, when a failure in the second power converter 340 causes power delivery to the 12V domain to become dependent on the third power converter 350, the power management system 160 may switch to the backup conversion path. In this configuration, the third power converter 350 is enabled to perform voltage conversion from the 48V domain to the 12V domain, as indicated by the thick dashed line extending across the third power converter 350 to the backup 12V bus 395.

[0044] Before a fault condition occurs, disconnector 370 may initially be in the closed state. By keeping disconnector 370 in the closed state, continuous monitoring of electrical conditions across connected power domains is possible. In one or more embodiments, disconnector 370 may include threshold-based sensing mechanisms that evaluate real-time parameters such as voltage and current. Upon detecting a fault condition, such as a rapid voltage drop on one side of disconnector 370 or a reversal of current direction exceeding expected tolerances, disconnector 370 may initiate a response by transitioning to the open state. This response, transitioning from the closed to the open state, helps isolate the fault domain to prevent fault propagation to other parts of the voltage domain and / or another voltage domain. In one or more embodiments, disconnector 370 may function as a bidirectional device, monitoring current flow in both directions and reacting when the current exceeds predefined operating limits. In one or more other embodiments, voltage levels across the bus may also be monitored to support accurate and timely fault detection.

[0045] Upon detecting that the disconnector switch 370 connected to the second power converter 340 has transitioned to an open state indicating a fault, the microcontroller may command the third power converter 350 to initiate power conversion. In one or more other embodiments, the microcontroller may maintain the disconnector switch 360 in a closed state to ensure uninterrupted power delivery between voltage domains.

[0046] In one or more embodiments, the voltage setpoint of the third power converter 350 may be configured to be slightly lower than the voltage setpoint of the second power converter 340. Under normal conditions, this allows for preferential power draw from the second power converter 340. Figure 3 In the event of a fault condition associated with the second power converter 340, the power management system 160 may passively switch to drawing power from the third power converter 350 due to losses from the higher voltage source (e.g., the second power converter 340 with a higher voltage setpoint). In one or more other embodiments, this form of load-sharing switching may be implemented via hardware logic independent of any active microcontroller intervention.

[0047] In one or more other embodiments, the third power converter 350 and the second power converter 340 can participate in active load balancing by operating the third power converter 350 in parallel with the second power converter 340 during normal system conditions. In this configuration, the third power converter 350 can continuously perform power conversion at a reduced or partial output level. If the second power converter 340 fails, the power management system 160 may not activate the third power converter 350 from its idle state, but instead increase its output level to compensate for the power deficiency.

[0048] Figure 5 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a second fault condition in a power management system 160, which includes multiple power converters with enhanced redundancy. For example... Figure 5 As shown, the first power converter 330 experiences a fault and becomes inoperable, such that failure to take corrective action could result in a complete power loss of all 48V subsystems (e.g., primary 48V bus 380 and backup 48V bus 385). To mitigate this situation, the power management system 160 can initiate a response in which the isolating switch 360 transitions to the open state to isolate the fault domain (e.g., the 48V domain). This action enables the bidirectional third power converter 350 to perform a voltage boost operation from the 12V domain to the 48V domain. This operation allows the third power converter 350 to supply power to the backup 48V bus 385 via the closed isolating switch 370.

[0049] Control of this transition can be passively initiated via voltage setpoint priority indices, where the third power converter 350 has a lower voltage reference than the first power converter 330 under normal operation, or actively initiated by a hardware or software monitoring subsystem that detects a fault and commands an appropriate isolating switch state change. This response can facilitate continuous power availability of the 48V subsystem by rerouting power via the third power converter 350 and maintaining the integrity of backup power paths in the 48V domain (e.g., backup 48V bus 385).

[0050] Figure 6 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a third fault condition in a power management system 160, which includes multiple power converters with enhanced redundancy. For example... Figure 6 As shown, a third power converter 350. In the event of a fault condition, the third power converter 350 ceases its conversion function, which may not significantly affect the operation of the primary power bus and the backup power path. For example, each voltage domain can still supply power to its primary (e.g., primary 48V bus 380, primary 12V bus 390) and backup power path (e.g., backup 48V bus 385, backup 12V bus 395). Although the third power converter 350 may become inoperable, the primary and backup buses continue to operate normally without interruption, thus contributing to the redundancy of power supply to the subsystem from the primary bus and the backup power path.

[0051] If the third power converter 350 stops outputting power, disconnect switches 360 and 370 may not need to react unless a short circuit or undervoltage condition exists. In the absence of these conditions, the power management system 160 may continue to operate without triggering either disconnect switch 360 or 370. Maintaining sufficient power availability to allow the vehicle 100 and its occupants to stop safely is beneficial for the power management system 160. In one or more other embodiments, the power management system 160 may not be configured for extended operation, but rather to handle critical system failures and facilitate the safe stopping of vehicle movement.

[0052] In one or more other implementations, the two backup power paths may be internally short-circuited, potentially leading to a fault condition that grounds both backup buses. A short circuit observed in a backup power path can trigger the opening of a corresponding isolating switch (e.g., 360, 370), effectively isolating the faulty bus to prevent further propagation of the fault condition to either of the main buses. Despite this fault condition, the power management system 160 remains operational because the fault may not affect the main power bus. For example, at least one 48V power path and one 12V power path remain functional, allowing for continued power availability of specific low-voltage subsystems to maintain redundancy and system stability even if an internal short circuit or fault affects the backup power paths.

[0053] In one or more other embodiments, a fault condition can be detected in which an unregulated switching process may occur due to a damaged setpoint, causing the power management system 160 to attempt to draw excessive power from one voltage domain and push it into the opposite voltage domain. In this case, the third power converter 350 may fail to regulate properly, drawing too much power in the wrong direction. This can lead to the activation of isolating switches 360, 370, which switch to the open state to prevent further damage. Thus, the two affected backup power paths can be isolated, while at least one 48V power path and one 12V power path can continue to operate, thereby facilitating the maintenance of power availability.

[0054] Figure 7 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a fourth fault condition in a power management system 160, which includes multiple power converters with enhanced redundancy. For example... Figure 7 As shown, the power path to the backup 12V bus 395 experiences a fault, with a short circuit occurring on the internal wiring between the third power converter 350 and the backup 12V bus 395. In this situation, the response involves stopping the conversion process of the third power converter 350, and the isolating switch 370 is switched to the open state to prevent further damage. For example, the first power converter 330 may supply power to both the primary 48V bus 380 and the backup 48V bus 385, while the second power converter 340 supplies power to the primary 12V bus 395. The backup 12V bus 395 remains isolated from the 12V domain by being kept in the open state by the isolating switch 370, and is isolated from the 48V domain by the third power converter 350 stopping its conversion operation.

[0055] This reconfiguration facilitates the protection of the voltage domain by the third power converter 350 by halting its switching process, while simultaneously isolating the voltage domain protected by the disconnector switch 370 from the fault. In the event that the third power converter 350 continues to erroneously switch, the disconnector switch 370 can be switched back to the open state, providing an additional layer of protection. This dual-protection approach enhances the reliability of the power management system 160 by isolating faults from critical low-voltage subsystems and maintaining overall system integrity.

[0056] Figure 8 Conceptually exemplified according to one or more specific implementations Figure 3 An example of a fifth fault condition in a power management system 160, which includes multiple power converters with enhanced redundancy. For example... Figure 8 As shown, the power path to the main 12V bus 390 experiences a fault, with a short circuit occurring on the external line between the second power converter 340 and the main 12V bus 390. If the fault occurs on the external load side, the isolating switch 370 switches to the open state, thereby protecting the backup 12V bus 395 from the fault. In one or more embodiments, the third power converter 350 can detect the fault and / or receive a command indicating the fault, thereby initiating a power conversion from the 48V domain to supply power to the backup 12V bus 395. Figure 8 As shown, isolating switch 370 remains open during fault conditions to protect the backup 12V bus 395 and the 48V domain from faults, while isolating switch 360 remains closed to facilitate power conversion from the 48V domain to the 12V domain via the third power converter 350. This configuration facilitates the maintenance of the backup power system's operational capability by redirecting power from the higher voltage domain (e.g., 48V) to the backup 12V bus 395 as needed.

[0057] Figure 9 Conceptually exemplified according to one or more specific implementations Figure 3 An example of the load balancing function in a power management system 160, which includes multiple power converters with enhanced redundancy. In addition to supplying power to the load, the power management system 160 also performs load balancing, which allows for compensation between two voltage domains. (As...) Figure 9 As shown, the first power converter 330 may operate in an insufficient manner, meaning that the power supplied by the first power converter 330 is less than the total power drawn by the 48V bus (e.g., primary 48V bus 380 and backup 48V bus 385). To offset this deficiency, the second power converter 340 provides 12V power at a level exceeding the power consumption of the 12V bus (e.g., primary 12V bus 390 and backup 12V bus 395).

[0058] The power management system 160 can initiate energy transfer, making the load balancing function involve bidirectional energy flow. For example, excess energy generated by the second power converter 340 that is not consumed by the 12V bus is routed through the third power converter 350 while the second disconnect switch 370 remains closed to perform a 12V to 48V conversion. With the first disconnect switch 360 closed, the converted power is routed from the third power converter 350 to the first power converter 330. This converted power can supplement the power shortage at the first power converter 330. The result of this operating state is that the power drawn from the second HV battery pack 320 is net increased compared to the power drawn from the first HV battery pack 310, causing the second HV battery pack 320 to discharge at a faster rate than the first HV battery pack 310. The load balancing process can continue until the state of charge (SOC) of the first HV battery pack 310 and the second HV battery pack 320 is balanced at a lower SOC level (e.g., approximately 42%). At this equilibrium point, the first power converter 330, the second power converter 340, and the third power converter 350 can return to balanced operating conditions, where there is neither an excess condition nor a deficiency condition.

[0059] In one or more specific implementations, the load balancing process can be categorized into three stages. The first stage can refer to passive balancing, where resistors are used to slowly balance the charge between the two sides within the battery pack 110 (or across the first HV split battery pack 310 and the second HV split battery pack 320, respectively). The second stage can refer to load balancing, where more power is intentionally drawn from one side to equalize the energy. The final stage can refer to active balancing, where energy is transferred from one side to the other to achieve an equal state between the two sides.

[0060] Figure 10 Conceptually exemplified according to one or more specific implementations Figure 3An example of an active balancing function in a power management system 160, which includes multiple power converters with enhanced redundancy, is provided. Active balancing between two battery packs (e.g., a first HV split battery pack 310 and a second HV split battery pack 320) may involve transferring energy via a conversion chain to equalize the energy stored in each battery pack. The power management system 160 may initiate energy transfer such that the active balancing function involves bidirectional energy flow. In cases where one battery pack is used more frequently than the other, such as one battery pack being used at 70% and the other at 30%, this imbalance may cause the more frequently used battery pack to deplete faster, resulting in earlier depletion of available energy. In one or more embodiments, energy can be converted and transferred between battery packs via a balancing mechanism when one battery pack reaches a lower state of charge (e.g., 35%) while the other is at 45%. This process helps to balance the state of charge, bringing the two battery packs closer to equal levels, such as 40% for each. The active balancing process can be performed gradually, resulting in smaller adjustments to the charge, optimizing energy use and extending the operational life of both battery packs.

[0061] Figure 11 This is a flowchart illustrating the exemplary operation of an enhanced over-the-air programming process 1100 for a power management integrated circuit, based on one or more specific implementations. The flowchart may be implemented by the power management system shown and / or described herein. For illustrative purposes, this document primarily refers to… Figure 1A and Figure 1B 100 means of transportation Figure 1A , Figure 1B and Figures 3 to 10 Power management system 160 Figures 3 to 10 The first HV split battery pack 310, Figures 3 to 10 The second HV split battery pack 320, Figures 3 to 10 First power converter 330 Figures 3 to 10 Second power converter 340 Figures 3 to 10 The process 1100 is described using the third power converter 350 and / or its various components. However, the process 1100 is not limited to... Figure 1A and Figure 1B 100 means of transportation Figure 1A , Figure 1B and Figures 3 to 10 Power management system 160 Figures 3 to 10 The first HV split battery pack 310, Figures 3 to 10 The second HV split battery pack 320, Figures 3 to 10 First power converter 330 Figures 3 to 10 Second power converter 340 Figures 3 to 10The third power converter 350, and one or more blocks (or operations) of process 1100 may be performed by vehicle 100 and / or other suitable mobile devices, equipment, or systems, or by one or more other structural components. Furthermore, for illustrative purposes, some blocks of process 1100 are described herein as occurring sequentially or linearly. However, multiple blocks of process 1100 may occur in parallel. Moreover, blocks of process 1100 do not need to be performed in the order shown, and / or one or more blocks of process 1100 need not be performed and / or may be replaced by other operations.

[0062] At block 1110, power management system 160 can supply power from a first power source (e.g., first power converter 330) to a first power converter (e.g., first HV split battery pack 310).

[0063] At block 1120, the power management system 160 can convert power from the first power converter 330 to a first voltage domain (e.g., 48V). In one or more embodiments, power can be supplied from the first power converter 330 to the primary load (e.g., primary 48V bus 380) and redundant loads (e.g., spare 48V bus 385) in the first voltage domain via a first disconnect switch (e.g., first disconnect switch 360). For example, when the first disconnect switch 360 is closed, power is supplied to the spare 48V bus 385.

[0064] At box 1130, power management system 160 can supply power from a second power source (e.g., second power converter 340) to a second power converter (e.g., second HV split battery pack 320).

[0065] At block 1140, the power management system 160 can convert power from the second power converter 340 to a second voltage domain (e.g., 12V). In one or more embodiments, power can be supplied from the second power converter 340 to the primary load (e.g., primary 12V bus 390) in the second voltage domain and to redundant loads (e.g., spare 12V bus 395) in the second voltage domain via a second disconnect switch (e.g., second disconnect switch 370). For example, when the second disconnect switch 370 is closed, power is supplied to the spare 12V bus 395.

[0066] At block 1150, power management system 160 is operatively coupled to a third power converter (e.g., third power converter 350) between a first voltage domain (e.g., 48V) and a second voltage domain (e.g., 12V). In this respect, power management system 160 can provide bidirectional power transfer between the first voltage domain (e.g., 48V) and the second voltage domain (e.g., 12V) via third power converter 350. In some aspects, third power converter 350 can transfer power between the first and second voltage domains based on fault conditions. In one or more embodiments, upon detection of a fault associated with the first voltage domain (e.g., 48V), first disconnector switch 360 can switch to an open state. Therefore, redundant loads in the first voltage domain (e.g., a spare 48V bus 385) can be disconnected from first power converter 330. In one or more embodiments, when first disconnector switch 360 is open, power can be transferred from the second voltage domain (e.g., 12V) to the first voltage domain (e.g., 48V) via third power converter 350. When the first disconnect switch 360 is open, the third power converter 350 can supply converted power to redundant loads in the first voltage domain (e.g., a spare 48V bus 385). In one or more other embodiments, when the second disconnect switch 370 is open, power can be converted from the first voltage domain (e.g., 48V) to the second voltage domain (e.g., 12V) by the third power converter 350. When the second disconnect switch 370 is open, the third power converter 350 can supply converted power to redundant loads in the second voltage domain (e.g., a spare 12V bus 395).

[0067] The methods described herein, combining direct sensing, integrated temperature monitoring, and strategic packaging, represent a approach to low-voltage battery management in electric vehicles. The methods, systems, or devices disclosed herein can be incorporated into electric vehicles or other devices. The circuit blocks disclosed herein can be distributed or combined with one or more ECUs or other devices. The methods, systems, or devices disclosed herein can be incorporated into products such as various feature-specific or region-specific electronic control units (ECUs).

[0068] Unless otherwise stated, the term "or" is used inclusively. As used herein, the phrase "at least one of" following a series of items, together with the terms "and" or "or" used to separate any items, modifies the entire list, not each member of the list (i.e., each item). The phrase "at least one of" does not require selection of at least one of each of the listed items; rather, the phrase allows for the inclusion of the meaning of at least one of any of these items, and / or at least one of any combination of these items, and / or at least one of each of these items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" respectively refer to only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0069] When a component is referred to herein as “connected” or “coupled” to another component, it should be understood that the component may be directly connected to that other component, or that there may be intermediate components between these components. Conversely, when a component is referred to herein as “directly connected” or “directly coupled” to another component, it should be understood that there are no intermediate components in the “direct” connection between these components. However, the presence of a direct connection does not preclude the possibility of other connections having intermediate components.

[0070] The predicates “configured to,” “operable to,” and “programmed to” do not imply any particular tangible or intangible modification of the subject matter, but are intended to be used interchangeably. In one or more embodiments, a processor configured to monitor and control operations or components may also mean that the processor is programmed to monitor and control operations or that the processor is operable to monitor and control operations. Similarly, a processor configured to execute code can be interpreted as a processor programmed to execute code or operable to execute code.

[0071] Phrases such as one aspect, aspect, on the other hand, some aspects, one or more aspects, one implementation, implementation, another implementation, some implementations, one or more implementations, one implementation scheme, implementation scheme, another implementation scheme, some implementation schemes, one or more implementation schemes, one configuration, configuration, another configuration, some configurations, one or more configurations, subject matter technology, disclosure, this disclosure, other variations thereof, and similar phrases are for convenience and do not imply that the disclosure associated with such phrases is necessary for the subject matter technology, or that such disclosure applies to all configurations of the subject matter technology. The disclosure associated with such phrases may apply to all configurations or one or more configurations. One or more examples of the disclosure associated with such phrases may be provided. Phrases such as one aspect or some aspects may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0072] The term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” or “example” is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, with regard to the use of terms such as “comprising,” “having,” etc., in the description or claims, such terms are intended to be inclusive in a manner similar to the term “including,” as interpreted when “including” is used as a transition word in the claims.

[0073] All structural and functional equivalents of elements of the various aspects described throughout this disclosure that are known to a person skilled in the art or will later be known are expressly incorporated herein by reference and are intended to be covered by the claims. Furthermore, nothing disclosed herein is intended to serve the public, whether or not such disclosure is expressly stated in the claims. No claim element should be subject to 35 USC. As defined in paragraph 6 of 112, unless the phrase “component for…” is used to explicitly state the element, or, in the case of a method claim, the phrase “step for…” is used to state the element.

[0074] The foregoing description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects. Therefore, the claims are not intended to limit them to the aspects shown herein, but are to be consistent with the full scope of the language claims, wherein elements referred to in the singular are not intended to mean “one and only one” but rather “one or more” unless specifically stated otherwise. Unless otherwise specifically stated, the term “some” refers to one or more. Male pronouns (e.g., his) include female and neutral pronouns (e.g., her and its), and vice versa. Titles and subheadings (if any) are used for convenience only and do not limit this disclosure.

Claims

1. A system comprising: A first power converter is configured to receive power from a first power source and convert the received power to a first voltage domain, wherein the power from the first power converter is provided to a first power path, the first power path including a primary load and a redundant load in the first voltage domain. A second power converter is configured to receive power from a second power source and convert the received power to a second voltage domain different from the first voltage domain, wherein the power from the second power converter is provided to a second power path, the second power path including a primary load in the second voltage domain and a redundant load in the second voltage domain. and A third power converter is coupled between the first voltage domain and the second voltage domain, wherein the third power converter is configured to transmit power between the first power path and the second power path based on a fault condition.

2. The system according to claim 1, further comprising: A first disconnecting switch is coupled to the first power converter and configured to selectively couple the redundant load in the first voltage domain to the first power converter. and A second isolating switch is coupled to the second power converter and configured to selectively couple the redundant load in the second voltage domain to the second power converter.

3. The system of claim 2, wherein the third power converter is coupled between the first disconnect switch and the second disconnect switch.

4. The system of claim 2, wherein the first disconnect switch is configured to open upon detection of a fault associated with the first voltage domain, and wherein when the first disconnect switch is open, the redundant load in the first voltage domain is disconnected from the first power converter.

5. The system of claim 4, wherein the third power converter is configured to convert power from the second voltage domain to the first voltage domain to supply power to the redundant load in the first voltage domain when the first disconnect switch is open.

6. The system of claim 2, wherein the second disconnect switch is configured to open upon detection of a fault associated with the second voltage domain, and wherein when the second disconnect switch is open, the redundant load in the second voltage domain is disconnected from the second power converter.

7. The system of claim 6, wherein the third power converter is configured to convert power from the first voltage domain to the second voltage domain to supply power to the redundant load in the second voltage domain when the second disconnect switch is open.

8. A power conversion system for a vehicle, the power conversion system comprising: A first power converter is configured to generate power in a first voltage domain and supply the power to a primary load and a redundant load in the first voltage domain via a first disconnecting switch. A second power converter is configured to generate power in a second voltage domain and supply the power to the primary load and redundant load in the second voltage domain via a second disconnecting switch. and A third power converter is coupled between the first disconnect switch and the second disconnect switch. The first disconnect switch is configured to open in response to detecting a fault associated with the first voltage domain, and to disconnect the redundant load in the first voltage domain from the first power converter. The second isolating switch is configured to open in response to detecting a fault associated with the second voltage domain, and to disconnect the redundant load in the second voltage domain from the second power converter. The third power converter is configured as follows: When the first disconnecting switch is open, power is switched from the second voltage domain to the first voltage domain, and power is supplied to the redundant loads in the first voltage domain. When the second disconnecting switch is open, power is switched from the first voltage domain to the second voltage domain, and power is supplied to the redundant load in the second voltage domain.

9. The power conversion system of claim 8, wherein each of the first disconnect switch and the second disconnect switch includes a fault detection circuit configured to monitor electrical faults in the first voltage domain and the second voltage domain, respectively.

10. The power conversion system of claim 8, wherein the third power converter is bidirectional and configured to transmit power between the first voltage domain and the second voltage domain to supply power to one or more of the redundant loads in the first voltage domain and the redundant loads in the second voltage domain.

11. The power conversion system of claim 8, wherein the first voltage domain and the second voltage domain operate at different voltage levels.

12. The power conversion system of claim 8, further comprising a controller communicatively coupled to the first disconnect switch, the second disconnect switch, and the third power converter, wherein the controller is configured to: Detect a fault in either the first voltage domain or the second voltage domain; Based on the fault, a disconnection command is sent to either the first disconnector or the second disconnector. as well as The third power converter is activated, at least in part, based on the fault, to provide power in either the first voltage domain or the second voltage domain.

13. A method for converting electricity in a vehicle, the method comprising: Power from the first power source is supplied to the first power converter; Power from the second power source is supplied to the second power converter; The power at the first power converter is converted to the first voltage domain; The power at the second power converter is converted to the second voltage domain; as well as An operation is performed on a third power converter coupled between the first voltage domain and the second voltage domain, wherein the third power converter transmits power between the first voltage domain and the second voltage domain based on a fault condition.

14. The method of claim 13, further comprising supplying power from the first power converter to the primary load and the redundant load in the first voltage domain via a first disconnecting switch.

15. The method according to claim 14, further comprising: Disconnect the first isolating switch when a fault associated with the first voltage domain is detected; as well as Disconnect the redundant load in the first voltage domain from the first power converter.

16. The method according to claim 15, further comprising: When the first disconnecting switch is open: The third power converter converts electricity from the second voltage domain to the first voltage domain. as well as When the first disconnecting switch is open, power is supplied from the third power converter to the redundant load in the first voltage domain.

17. The method of claim 13, further comprising supplying power from the second power converter to the primary load and the redundant load in the second voltage domain via a second disconnecting switch.

18. The method according to claim 17, further comprising: Disconnect the second isolating switch when a fault associated with the second voltage domain is detected; as well as Disconnect the redundant load in the second voltage domain from the second power converter.

19. The method according to claim 18, further comprising: When the second disconnecting switch is open: The third power converter converts electricity from the first voltage domain to the second voltage domain. as well as Power is supplied from the third power converter to the redundant load in the second voltage domain.

20. The method of claim 13, further comprising providing bidirectional power transfer between the first voltage domain and the second voltage domain via the third power converter.

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