Switching Regulator for Vehicle Alternator Power Control
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Solution Overview
Problem
Existing vehicle charging and distribution systems face inefficiencies due to variations in alternator output power with speed, leading to inadequate battery charging and power distribution, especially at low speeds, resulting in reduced battery lifespan and increased costs due to heat dissipation and power losses.
Innovation Solution
A system comprising a switching regulator and a control circuit that selectively operates in different states based on alternator speed and output voltage to maximize power transfer, using a boost semi-bridge switched mode rectifier at lower speeds and a shunt regulator at higher speeds, along with a converter to provide a constant current for battery charging and load power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional alternator charging system is used, then the system structure is simple, but the battery charging efficiency is insufficient especially at low speeds due to alternator output power variations
Solution Approach 1:
The patent implements dynamic operation of the switching regulator that adapts to different alternator speed ranges. The regulator transitions between different operating states (first state for low speeds, second state for high speeds) to optimize power transfer efficiency across the entire alternator speed range, thereby improving battery charging efficiency without requiring a fundamentally complex system architecture
Solution Approach 2:
The switching regulator dynamically adjusts its operating parameters based on alternator speed. At low speeds, it operates in a first state with specific duty cycle ranges to maximize power transfer; at high speeds, it transitions to a second state with different duty cycle ranges. This parameter adaptation resolves the contradiction by maintaining high charging efficiency across varying speed conditions while using a relatively simple switching regulator structure
2Use of energy by moving object
If the alternator operates at low speed, then fuel consumption is reduced, but the alternator output power is insufficient for adequate battery charging and load power distribution
Solution Approach 1:
The system dynamically adjusts the switching regulator's duty cycle based on real-time alternator speed measurements. When the alternator operates at low speeds (reducing fuel consumption), the regulator compensates by operating in a first state with optimized duty cycle ranges that maximize the limited power output. This dynamic adaptation allows the system to maintain adequate charging and power distribution even at low alternator speeds, resolving the contradiction between fuel efficiency and power output
3Productivity
If the switching regulator operates without selective state control, then the control system is simple, but power losses and heat dissipation increase reducing overall efficiency
Solution Approach 1:
The control circuit selectively changes the switching regulator's operating state based on alternator speed parameters. In the first operative state (for lower speeds), the regulator uses duty cycle ranges of approximately 20-80% to optimize power transfer and minimize losses. In the second operative state (for higher speeds), it uses duty cycle ranges of approximately 40-90%. This parameter adaptation reduces power losses and heat dissipation across different operating conditions, thereby improving overall power transfer efficiency
Solution Approach 2:
The control circuit continuously monitors alternator speed and output voltage, and uses this feedback to selectively transition the switching regulator between operating states. This closed-loop control ensures that the regulator operates in the optimal state for current conditions, minimizing power losses and heat dissipation while maximizing power transfer efficiency. The feedback mechanism adds control complexity but resolves the contradiction by enabling adaptive optimization
4Adaptability or versatility
If a single operating state is used for the switching regulator, then the device complexity is low, but the adaptability to different alternator speeds and load conditions is insufficient
Solution Approach 1:
The control circuit implements dynamic state selection based on alternator speed and load conditions. The regulator transitions between a first operative state for lower speeds and a second operative state for higher speeds, with transition thresholds that can be adjusted based on system requirements. This dynamic adaptability allows the system to respond to varying alternator speeds and load conditions effectively, while the control circuit complexity remains manageable through the use of predefined state transitions and threshold-based control logic
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures efficient power generation and distribution across the entire alternator speed range, reducing size and cost, improving battery life, and enhancing fuel efficiency by optimizing power utilization and management.
Implementation Method 1
the charging systems in the vehicle include an alternator that is used to convert mechanical energy from a vehicle engine into electrical energy
Implementation Method 2
The switching regulator is further configured to selectively operate in one of a first operative state and a second operative state based on a control signal
Implementation Method 3
The first converter is coupled with the switching regulator and is configured to generate a first converter output voltage based on the regulated DC output voltage, such that the first converter output voltage is lower than the regulated DC output voltage
Data Source
AI summary
A system configured for charging and distribution control is provided. The system includes a switching regulator, a control circuit and a first converter. The switching regulator is configured to be selectively operable in one of a first operative state and a second operative state based on a control signal. The first operative state and the second operative state are associated with a maximum level of an alternator output power corresponding to at least one alternator operational feature, at least one alternator operational feature being associated with the alternator output voltage and an alternator speed. The control circuit is configured to generate the control signal based at least on the at least one alternator operational feature. The first converter is configured to generate a first converter output voltage based on the regulated DC output voltage. The first converter output voltage is lower than the regulated DC output voltage.