Integrated DC-DC Converter Control for EV-to-EV Battery Charging

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Solution Overview

Problem

Current high-voltage electrical systems for vehicle-to-vehicle (V2V) charging of electrified vehicles face challenges in efficiently managing and modulating the power transfer between vehicles, particularly in terms of voltage regulation and energy distribution.

Innovation Solution

The implementation of a high-voltage electrical system architecture that includes a smart integrated DC-DC converter, capable of operating in both bypass and V2V modes, to step-up or step-down power input received from a donor vehicle based on the host vehicle's state-of-charge, voltage, and power limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a DC-DC converter is integrated into the HV electrical system for V2V charging, then voltage regulation and power modulation capability is improved, but device complexity increases

Engineering Contradiction:

Improvevoltage regulation capabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates the DC-DC converter directly into the HV electrical system architecture, merging the power conversion function with the existing charging infrastructure. This consolidation eliminates the need for separate external voltage regulation devices and reduces overall system complexity while maintaining adaptability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The DC-DC converter is designed to perform multiple functions including voltage regulation, power modulation, and bidirectional power flow management during V2V charging. This multi-functionality allows a single device to handle various charging scenarios and voltage conditions, improving versatility without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If external contactors and HV-cable splices are used for V2V charging connections, then ease of connection is improved, but reliability and safety deteriorate due to additional connection points

Engineering Contradiction:

Improveconnection easeVSAvoidcharging reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent eliminates external contactors and HV-cable splices from the V2V charging connection path by integrating the power conversion function directly into the vehicle's HV system. This extraction of unnecessary intermediate components reduces the number of connection points, thereby improving reliability while maintaining operational simplicity through direct integrated connections.

Inventive Principle:

Principle #2Taking out (Extraction)

3Speed

If power input is directly transferred without modulation, then energy distribution speed is improved, but adaptability to different voltage levels and power limits deteriorates

Engineering Contradiction:

Improvepower transfer speedVSAvoidvoltage level adaptability

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The DC-DC converter enables dynamic power modulation by continuously adjusting conversion ratios based on real-time voltage levels and power limits of both donor and recipient vehicles. This dynamic adaptation allows efficient power transfer at varying voltage levels without sacrificing transfer speed, as the converter responds automatically to changing conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters including conversion ratio, output voltage, and current limits based on the specific voltage levels and power capabilities of the connected vehicles. This parameter adaptation ensures optimal power transfer efficiency and compatibility across different voltage platforms while maintaining fast charging speeds.

Inventive Principle:

Principle #35Parameter changes

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 and flexible V2V charging by dynamically modulating the DC power transfer, optimizing energy distribution, and reducing the need for external contactors or HV-cable splices, thereby enhancing the overall charging efficiency and safety.

Implementation Method 1

a DC-to-DC (DC-DC) converter that is electrically interposed between and electrically connects the charging inlet port and the main HV bus, the DC-DC converter being operable in a bypass mode, in which the DC-DC converter passes therethrough DC power

Methodology Applied

Scientific EffectElectrical energy transformation: Electromagnetic Induction

Data Source

PatentUS20250178461A1Electrified vehicles, battery system architectures, and control logic for vehicle-to-vehicle charging

Publication Date: 2025.06.05 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Presented are high-voltage (HV) electrical system architectures for vehicle-to-vehicle (V2V) charging of vehicle batteries, methods for making/using such systems, and vehicles equipped with such systems. An HV electrical system for a motor vehicle includes a main HV bus that electrically connects the vehicle's traction motor(s) to the vehicle's battery pack(s), and a charging inlet port that electrically mates with and receives direct-current (DC) power from DC fast-charging (DCFC) cables of a donor vehicle and a charging station. A DC-to-DC (DC-DC) converter is interposed between and electrically connects the charging inlet port to the main HV bus. The DC-DC converter is operable in a bypass mode, in which the DC-DC converter passes therethrough DC power received from the DCFC cable of the charging station, and a vehicle-to-vehicle (V2V) mode, in which the DC-DC converter modulates DC power received from the DCFC cable of the donor vehicle.