Bidirectional Vehicle Power Converter for Fault-Tolerant Drive Supply

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Solution Overview

Problem

Existing vehicle on-board power supply systems are unfit for operation in case of faults in the voltage converter or electric machine, posing safety risks to occupants.

Innovation Solution

A bidirectional rectifier, or basic voltage converter, capable of converting between alternating and direct current, operates in redundancy mode to provide a redundant power supply to the electric drive motor, switching between power sources as needed to ensure continuous energy supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single voltage converter is used in the power supply system, then the device complexity is reduced, but the reliability deteriorates because the vehicle becomes unfit to drive in case of fault

Engineering Contradiction:

Improvepower supply system structureVSAvoidoperational safety

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The basic voltage converter is designed to perform multiple functions: it can operate as a rectifier in charging mode to convert AC from the power grid into DC for the power storage unit, and as an inverter in redundancy operating mode to convert DC from the power storage unit into AC for supplying power to the electric drive motor. This multi-functionality eliminates the need for separate redundant voltage converters while maintaining reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The basic voltage converter dynamically switches between different operating modes (charging mode and redundancy operating mode) based on system requirements. The converter can transition from rectification to inversion operations, adapting its function in real-time to maintain power supply reliability while using a single device

Inventive Principle:

Principle #15Dynamics

2Reliability

If redundant voltage converters are installed to ensure continuous operation, then the reliability is improved, but the device complexity increases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidpower supply system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of installing multiple dedicated voltage converters, the system uses a single basic voltage converter that can perform both rectification and inversion operations. This multi-functional approach provides redundancy capability without duplicating the entire voltage converter system, thereby maintaining reliability while avoiding increased device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the basic voltage converter operates in redundancy mode, then the reliability is improved by providing alternative power supply, but the energy efficiency deteriorates due to additional conversion processes

Engineering Contradiction:

Improvepower supply continuityVSAvoidenergy conversion loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The basic voltage converter enables continuous useful action by maintaining the ability to supply power to the electric drive motor through redundancy operating mode. When the main voltage converter fails, the basic converter seamlessly takes over, ensuring continuous operation without interruption, thereby prioritizing reliability over minimal energy loss

Inventive Principle:

Principle #20Continuity of useful action

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 continuous operation of the vehicle by providing a redundant power supply, preventing safety risks and extending battery life through intelligent switching and monitoring, while allowing efficient energy management and grid stabilization.

Implementation Method 1

convert, in a charging mode, an alternating current from a power grid into a direct current for a power storage unit (in the sense of rectification)

Methodology Applied

Scientific EffectRectification:

Implementation Method 2

convert, in a redundancy operating mode, a direct current of the power storage unit and/or a direct current of a fuel cell and/or a current, such as direct current or alternating current, of a generator into an alternating current for supplying power to an electric drive motor (in the sense of inversion)

Methodology Applied

Scientific EffectInversion:

Data Source

PatentUS20250269726A1Electrical Circuit, On-Board Power Supply System, Vehicle, Method, Computer Program, And Computer-Readable Medium

Publication Date: 2025.08.28 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

An electrical circuit for a vehicle is provides. The electric circuit includes a basic voltage converter which is designed to convert, in a redundancy operating mode, a direct current of a power storage unit into an alternating current for supplying power to an electric drive motor. An on-board power supply system, a vehicle, a method, a computer program, and a computer-readable medium are also provided.