Standalone Booster Module for DC Bus Ripple Energy Storage
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Solution Overview
Problem
Existing automotive power systems face challenges in efficiently managing current flow and energy storage, particularly with the large size of electrolytic capacitor banks in battery current control modules, which can consume a significant portion of the overall package volume and introduce issues.
Innovation Solution
Implementing an active ripple energy storage circuit using a standalone booster module connected to a high voltage DC bus, which reduces the size of electrolytic capacitor banks and manages energy storage and discharge efficiently, synchronized with AC grid voltage to minimize ripple current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrolytic capacitor banks are used for energy storage in the battery current control module, then energy storage capacity is improved, but device volume increases significantly
Solution Approach 1:
The energy storage function is segmented from the battery current control module by introducing a standalone booster module. The booster module contains the electrolytic capacitor bank, separating the energy storage function from the control module, thereby reducing the control module's volume while maintaining overall energy storage capacity.
Solution Approach 2:
The booster module acts as an intermediary component between the battery current control module and the DC bus. It mediates the energy transfer by storing energy in its capacitor bank and releasing it when needed, enabling the system to achieve the desired energy storage without increasing the main control module's volume.
2Quantity of substance
If electrolytic capacitor banks are used for energy storage, then energy storage capacity is improved, but device complexity increases
Solution Approach 1:
The system is divided into functionally independent modules: the battery current control module and the standalone booster module. Each module has a specific function, which simplifies the design and reduces the complexity within each individual module, even though the overall system has more components.
Solution Approach 2:
The booster module serves multiple functions: it provides energy storage, performs voltage boosting, and filters ripple current. By consolidating these functions into a single standalone module, the overall system complexity is managed more effectively than distributing these functions across multiple components in the main control module.
3Adaptability or versatility
If AC current is delivered to the bus from an AC source, then power supply flexibility is improved, but current ripple increases
Solution Approach 1:
The booster module operates in periodic cycles, alternately charging its capacitor bank from the bus and discharging to the bus. This periodic operation is synchronized with the AC grid voltage, creating a rhythm that counteracts the ripple current and smooths the current delivered to the battery.
Solution Approach 2:
The booster module converts the harmful ripple current into a beneficial effect by using the capacitor bank to store energy during ripple peaks and release it during valleys. The controller synchronizes this operation with the AC grid voltage, transforming the ripple from a harmful factor into an opportunity for efficient energy management.
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
The solution reduces the size of electrolytic capacitor banks by up to 70% and ensures uninterrupted battery charging with minimal ripple current, enhancing power density and efficiency.
Implementation Method 1
a booster module, including a capacitor connected with the bus between the battery current control module and traction battery
Data Source
AI summary
An automotive power system has a battery current control module including a bidirectional power factor correction circuit and an isolated DC/DC converter connected between a bus and the bidirectional power factor correction circuit. The system further has a traction battery connected with the bus, and a booster module including a capacitor connected with the bus between the battery current control module and traction battery.