Boost Converter Power Limiting Without Full Temperature Sensing

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Solution Overview

Problem

Existing fuel cell systems with boost converters require temperature sensors to prevent overheating, which becomes impractical with increasing numbers of capacitors, and they are not designed to handle short-term power surges beyond continuous rated power without risking overheating.

Innovation Solution

A fuel cell system that includes a boost converter, voltage sensor, current sensor, and a controller that uses pre-stored data and correspondence relations to estimate component temperatures and set upper power limits without a temperature sensor, allowing for efficient operation within safe power limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If temperature sensors are installed to measure capacitor temperatures in the boost converter, then overheating can be prevented, but the device complexity and cost increase significantly when the number of capacitors increases

Engineering Contradiction:
Improveoverheating preventionVSAvoidnumber of temperature sensors
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary measurement approach by measuring the temperatures of only two specific capacitors (first and second capacitors) instead of all capacitors. The controller uses these limited temperature measurements along with output power information to infer the thermal state of other capacitors, thereby preventing overheating without requiring temperature sensors for every capacitor.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a thermal model or correspondence relationship that copies the thermal behavior patterns from measured capacitors to unmeasured capacitors. By establishing relationships between capacitor temperatures and output power, the system can estimate temperatures of unmeasured capacitors based on measurements from a subset, reducing the number of required sensors while maintaining reliable overheating prevention.

Inventive Principle:
Principle #26Copying

2Reliability

If the boost converter operates at continuous rated electric power, then component protection is ensured, but the system cannot utilize short-term power surge capacity

Engineering Contradiction:
Improvecomponent protectionVSAvoidpower output capability
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent implements dynamic power limit adjustment by continuously monitoring capacitor temperatures and adapting the output power limit in real-time. When temperatures are low, the system allows operation above continuous rated power (utilizing short-term surge capacity). When temperatures approach thresholds, the system dynamically reduces the power limit to prevent overheating. This creates a dynamic balance between component protection and power output capability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the operating parameter (output power limit) based on temperature conditions. Instead of maintaining a fixed continuous rated power limit, the system adjusts the power limit parameter according to real-time temperature measurements and pre-established temperature-power correspondence relationships, enabling both component protection and efficient utilization of short-term power surge capacity.

Inventive Principle:
Principle #35Parameter changes

3Measurement precision

If multiple temperature sensors are installed to monitor all capacitors, then accurate temperature monitoring is achieved, but the manufacturing cost and system complexity increase

Engineering Contradiction:
Improvetemperature monitoring accuracyVSAvoidmanufacturing cost
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent uses output power as an intermediary parameter to infer temperatures of unmeasured capacitors. By measuring temperatures of only two capacitors and combining this data with output power information, the system can estimate temperatures of other capacitors through pre-established correspondence relationships, achieving comprehensive temperature monitoring without installing sensors on every capacitor.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent makes the measured temperature data and output power information serve multiple functions: directly monitoring measured capacitors, inferring temperatures of unmeasured capacitors through correspondence relationships, and dynamically adjusting power limits. This multi-functional use of limited measurement data achieves comprehensive monitoring with minimal sensors.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240313245A1Fuel cell system
Publication Date: 2024.09.19 TOYOTA JIDOSHA KK
  • US20240313245A1 patent drawing
  • US20240313245A1 patent drawing
  • US20240313245A1 patent drawing

AI summary

A fuel cell system includes a sensor. The controller decides a continuous rated electric power. The controller sets a time rated electric power as a final upper limit electric power when the time rated electric power is higher than the continuous rated electric power and is lower than an instantaneous upper limit electric power, and sets the instantaneous upper limit electric power as the final upper limit electric power when the time rated electric power is higher than the continuous rated electric power and is higher than the instantaneous upper limit electric power. When the time rated electric power is lower than the continuous rated electric power, the continuous rated electric power is set as the final upper limit electric power. The controller controls one of the boost converter and an FC such that the output of the boost converter does not exceed the final upper limit electric power.