Bi-directional MOSFET Switch Module for Vehicle Current Control
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Solution Overview
Problem
Current technologies lack a bi-directional switch module capable of effectively controlling and directing high electrical currents between bi-functional devices in vehicle electrical systems, such as batteries and alternators, while protecting against overcurrent, overheating, and other operational conditions.
Innovation Solution
A bi-directional switch module comprising a sensor and a controller, typically a microprocessor, that can switch electrical current on/off based on measured values, default values, and input values, ensuring the current magnitude and direction do not exceed predetermined thresholds, and can detect temperature and other operational parameters to protect the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a bi-directional switch module is designed to handle high currents (100-1000 amperes), then the current carrying capacity is improved, but the risk of overcurrent damage and overheating increases
Solution Approach 1:
The controller is pre-programmed with threshold values for current magnitude, rate of change, duration, and temperature. Before harmful overcurrent or overheating conditions occur, the controller continuously monitors these parameters and is ready to activate protection mechanisms by switching off the bi-directional switch when thresholds are exceeded, preventing damage before it occurs
Solution Approach 2:
The system implements continuous feedback through sensors that monitor current magnitude, rate of change, duration, and temperature. This feedback is fed to the controller which compares real-time values against pre-stored thresholds and dynamically adjusts the switching state accordingly, creating a closed-loop protection system that adapts to changing operating conditions
2Reliability
If the switch module continuously monitors multiple parameters (current magnitude, rate of change, duration, temperature), then the protection capability is improved, but the device complexity increases
Solution Approach 1:
The controller is designed as a multi-functional device that handles multiple monitoring tasks (current magnitude, rate of change, duration, temperature) and multiple protection functions (switching off under various fault conditions) within a single integrated unit. This universal controller consolidates what could be multiple separate devices, reducing overall system complexity while maintaining comprehensive protection capabilities
Solution Approach 2:
The controller monitors changes in multiple parameters simultaneously (current magnitude, rate of change, duration, temperature) and uses any of these parameter changes as triggers for protection activation. This multi-parameter approach allows comprehensive protection through a single control unit rather than requiring separate dedicated devices for each parameter
3Reliability
If the switch can detect and respond to various operating conditions (short circuit, overcurrent, overheating), then the safety is improved, but the response time and switching speed may be affected
Solution Approach 1:
When a fault condition is detected (short circuit, overcurrent, overheating), the controller immediately switches off the bi-directional switch without delay for additional checks or sequential processing. This rushing through the protection action ensures that harmful conditions are interrupted as quickly as possible, prioritizing safety over extended response time
Data Source
AI summary
A high current, light weight, thermally stable, bidirectional semiconductor switch module in an electrical system uses MOSFET technology in a back-to-back parallel architecture. The device comprises a controller which permits it to operate in high electrical noise environments. The device is further controlled to operate in either or both directions based on external events such as voltage changes associated with the electrical system and with vehicle operating conditions. The device operates at currents typically from a few amperes to 1000 amperes and may be used as a circuit breaker, over voltage switch, isolation switch, transient protection switch, and voltage converter. The device functions to replace the solenoids and relays associated with starter motors in a vehicle electrical system.