Vehicle Battery Charging Control for DC-DC Converter Failure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Faulty low power-rated DC to DC converters in vehicles lead to inadequate charging of low-voltage batteries, causing inconvenience and potential battery drain during key-off conditions.
Innovation Solution
A vehicle system that utilizes a high power-rated DC to DC converter to charge the low-voltage battery during key-off when the low power-rated converter fails, optimizing charging by shutting down non-essential loads, informing the user, and adjusting charging strategies based on battery health, converter health, and user return time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the low power-rated DC to DC converter is used to charge the low-voltage battery during key-off, then the battery charging function is provided, but the converter may become faulty resulting in no charging
Solution Approach 1:
The patent merges the charging function into the high power-rated DC to DC converter when the low power-rated converter becomes faulty. The control unit detects the fault and redirects the charging task to the high power-rated converter, ensuring continuous charging capability without requiring an additional backup converter, thus maintaining reliability while avoiding increased system complexity.
Solution Approach 2:
The high power-rated DC to DC converter is designed with multi-functionality, serving both as the primary converter during key-on operation and as a backup charging converter during key-off when the low power-rated converter fails. This universal design allows one converter to perform multiple roles, eliminating the need for dedicated backup hardware.
2Reliability
If the high power-rated DC to DC converter is used to charge the low-voltage battery, then charging capability is ensured, but wear and tear on the converter increases
Solution Approach 1:
The patent implements dynamic charging strategy where the control unit adjusts the charging parameters (current, voltage, duration) based on real-time monitoring of converter health status and battery state of charge. When the high power-rated converter is used for charging, the control unit reduces charging current and extends charging intervals to minimize thermal stress and electrical load, thereby reducing wear and extending the converter's service life while maintaining charging availability.
Solution Approach 2:
The control unit changes operational parameters of the high power-rated converter when used for charging the low-voltage battery. Instead of operating at full capacity, the converter operates at reduced power levels with adjusted current and voltage parameters, which reduces thermal generation and electrical stress, thereby minimizing wear and tear while still providing adequate charging function.
3Reliability
If continuous charging is provided to the low-voltage battery, then battery health is maintained, but energy consumption increases
Solution Approach 1:
The patent implements periodic charging action where the control unit monitors the low-voltage battery's state of charge and only activates charging when the battery level falls below a predetermined threshold. The charging process is interrupted when the threshold is reached and resumed when the battery discharges again. This periodic charging approach maintains battery health by preventing deep discharge while avoiding continuous energy consumption during periods when the battery is already sufficiently charged.
Solution Approach 2:
The control unit continuously monitors the low-voltage battery's state of charge, temperature, and health status, and uses this feedback information to dynamically adjust charging parameters. When the battery is healthy and charge level is adequate, charging is reduced or suspended. When the battery shows signs of degradation or low charge, the control unit increases charging frequency and intensity, thereby maintaining battery health while minimizing unnecessary energy consumption.
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
Ensures efficient low-voltage battery charging, minimizes wear and tear on the battery and converter, and informs the user to arrange for repairs, thereby maintaining vehicle functionality and battery health.
Implementation Method 1
The first DC to DC converter is configured to convert an HV electric power obtained from the HV battery to an LV electric power
Data Source
AI summary
A vehicle including a Direct Current-to-Direct Current (DC to DC) converter, a low-voltage battery, a memory and a processor is disclosed. The DC to DC converter may be configured to convert a high voltage electric power to a low voltage electric power, and the low-voltage battery may be configured to be charged by the DC to DC converter via the low voltage electric power. The memory may be configured to store inputs associated with a vehicle user. The processor may be configured to determine that a trigger event has occurred, and estimate a future vehicle usage based on the inputs responsive to determining that the trigger event has occurred. The processor may further control a charging operation of the low-voltage battery by the DC to DC converter based on the future vehicle usage.