Multi-Voltage DC-DC Converter with Integrated Charging Interface
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Solution Overview
Problem
Existing multi-voltage vehicle electrical systems with DC-DC converters are costly and space-intensive due to the need for separate charging devices and converters, which also lead to increased weight and fuel consumption.
Innovation Solution
Integrating a DC-DC converter with multiple phases that can operate in different modes, allowing at least one phase to be used for charging external devices while maintaining voltage conversion capabilities, thereby reducing the need for separate charging devices and optimizing component usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate charging device is provided in addition to the DC-DC converter, then the functionality of charging external devices is improved, but the device complexity, cost, and installation space increase
Solution Approach 1:
The patent combines the charging device functionality with the existing DC-DC converter by integrating a charging interface into the multi-voltage network. The DC-DC converter's output is connected to both the low-voltage level and the charging interface, allowing a single device to serve dual purposes: voltage conversion between high-voltage and low-voltage networks, and charging external devices. This eliminates the need for a separate charging device, reducing system complexity and installation space.
Solution Approach 2:
The DC-DC converter is designed to perform multiple functions: it converts high-voltage to low-voltage for the vehicle's electrical system and simultaneously provides charging capability for external devices through the integrated charging interface. This multi-functional design allows the same hardware component to serve both internal vehicle power needs and external charging requirements, improving versatility without increasing device complexity.
2Adaptability or versatility
If a separate charging device is provided in addition to the DC-DC converter, then the charging capability is improved, but the weight increases leading to higher fuel consumption
Solution Approach 1:
The charging device is merged with the DC-DC converter, sharing common components such as the power conversion circuitry, control system, and housing. By integrating these functions into a single device, the overall weight is reduced compared to having separate charging and voltage conversion devices. This weight reduction directly translates to lower fuel consumption in conventional vehicles.
3Power
If the DC-DC converter is designed to be multi-phase, then the power density and current-carrying capacity are improved, but the device complexity increases
Solution Approach 1:
The DC-DC converter is designed with multiple independent converter phases connected in parallel. Each phase operates independently with its own power switches and control, allowing the total power capacity to be divided into manageable segments. This segmentation enables higher power density and current-carrying capacity while maintaining modular complexity that is easier to control and manage compared to a single high-power phase.
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 approach reduces overall costs, minimizes installation space, saves weight, and allows for efficient use of components by combining voltage conversion and charging functions within a single system, thereby enhancing the functionality of the multi-voltage vehicle electrical system.
Implementation Method 1
a DC-DC converter, via which a high-voltage level with a higher DC voltage different from ground and at least one first energy storage device is connected to a low-voltage level with a lower voltage different from ground and at least one second energy storage device
Data Source
Figure 1~2
AI summary
The invention relates to a multi-voltage on-board power supply system for a motor vehicle having a hybrid or electric drive, comprising a dc-dc converter (DCDC), by means of which a high voltage level having a higher direct current different from earth and at least one first energy store (ES1) is connected to a low voltage level having a lower voltage different from earth and at least one second energy store (ES2). The multi-voltage on-board power supply system comprises a charging interface (S) for charging external devices. At least one converter phase of the dc-dc converter can be disconnected from the low voltage level and instead can be connected to the charging interface, and a third energy store (ES3) can be connected to the charging interface in order to supply the third energy store in the connected state with the lower voltage and to enable charging of the third energy store by energy flow from the first energy store to the third energy store.