Catalytic Converter Preheating with Integrated Dual-Voltage DC-DC Control
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Solution Overview
Problem
The existing 48V/4 kW electric heater for hybrid electric vehicles requires conversion from 300V to 48V, leading to large volume and high cost issues due to the need for additional DC-DC circuits, making industrial application challenging.
Innovation Solution
A three-way catalytic converter preheating control method and system utilizing a high-low-voltage conversion module to provide two working voltage modes, allowing digital control for preheating the catalyst when the exhaust pipe temperature is low, eliminating the need for additional DC-DC circuits by converting high-voltage to low-voltage and vice versa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a 48V/4 kW electric heater is added to preheat the catalyst, then the emission requirements can be met, but the system volume and cost increase due to requiring additional DC-DC circuits
Solution Approach 1:
The patent combines the 48V DC-DC circuit and 12V DC-DC circuit into a single integrated circuit that can output both voltage levels. The 48V output supplies the electric heater for catalyst preheating, while the 12V output maintains existing vehicle electrical systems. This merging eliminates the need for separate DC-DC converters, reducing system volume and cost while maintaining the ability to meet emission requirements through effective catalyst heating
2Power
If a split-type 48V external DC-DC is used, then the electric heater can be powered, but the system volume and cost increase
Solution Approach 1:
The integrated DC-DC circuit is designed to perform multiple functions: it provides 48V output for the high-power electric heater, 12V output for existing vehicle electrical systems, and can operate in different modes (48V-only mode, 12V-only mode, or dual-output mode) depending on vehicle requirements. This multi-functionality allows the single circuit to replace what would otherwise require separate dedicated circuits, reducing overall system volume while maintaining full power capability
3Device complexity
If an internally integrated 48V DC-DC is developed, then the system can be compact, but the development cost and complexity increase
Solution Approach 1:
The patent implements a controllable switching mechanism that dynamically selects between different operating modes based on real-time vehicle conditions. The control unit can switch between 48V output mode, 12V output mode, or dual-output mode depending on whether the electric heater is active, whether the vehicle is in hybrid or conventional mode, and other operational parameters. This dynamic adaptability allows the system to be manufactured as a single versatile platform rather than requiring different hardware configurations for different vehicle modes, reducing development cost and manufacturing complexity
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
This solution enables efficient preheating of the catalyst while reducing system size, cost, and facilitating industrial mass production, meeting stringent emission requirements with improved economic benefits.
Implementation Method 1
the 48V/4 kW electric heater must be converted from 300V to 48V DC before it can be used... the high-and-low-voltage-conversion module outputting a first working voltage
Implementation Method 2
the electric heating is used in advance. The heating method takes 1 to 2 minutes to quickly heat the catalyst to its working temperature
Data Source
AI summary
The invention provides a three-way catalytic converter preheating control method and system, a vehicle and a storage medium. The includes when the temperature of an exhaust pipe of the hybrid electric vehicle is lower than a first temperature threshold value, sending a first work instruction; the high-low pressure conversion module outputting a first working voltage according to the first working instruction so as to start preheating of a catalyst in a three-way catalytic converter; when working data of the hybrid electric vehicle meets the switching condition, sending a second working instruction to make the high-low voltage conversion module outputs a second working voltage and stops outputting the first working voltage so as to stop the electric heating. According to the invention, two working modes can be provided, and the power battery can be used for electrically heating the catalyst in advance through the high-low pressure conversion module.