DC-to-DC Converter with Dynamic Set-Point Control
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Solution Overview
Problem
As customer demand for increased electrical features in vehicles grows, existing DC-to-DC converters face challenges in efficiently managing electrical loads and optimizing power distribution, leading to suboptimal performance and fuel economy.
Innovation Solution
A dual board DC-to-DC converter system with a DC-to-DC module that dynamically adjusts a set-point threshold based on external inputs, operation parameters, and performance history to switch between single and dual converter modes, ensuring optimal efficiency and power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a typical DC-to-DC converter simply outputs voltage and current without active control, then the device complexity is reduced, but the efficiency of the DC-to-DC converter and vehicle system deteriorates
Solution Approach 1:
The patent implements dynamic control of the DC-to-DC converter by continuously monitoring power output and adjusting converter activation based on real-time conditions. The system transitions from static operation to dynamic adaptation, activating converters only when power output exceeds thresholds, thereby optimizing efficiency without excessive complexity
Solution Approach 2:
The system incorporates feedback mechanisms where the DC-to-DC module monitors power output from the primary converter and uses this information to control activation of the secondary converter. This closed-loop feedback enables efficient operation by adjusting converter states based on actual power delivery requirements
2Device complexity
If the set-point threshold is fixed, then the device complexity is reduced, but the adaptability to varying electrical loads deteriorates
Solution Approach 1:
The set-point threshold transitions from a fixed value to a dynamic parameter that adjusts based on operating conditions. The DC-to-DC module modifies the threshold according to power output levels and system state, enabling the system to adapt to varying electrical loads while maintaining manageable control complexity
Solution Approach 2:
The patent changes the set-point threshold parameter dynamically based on system operation. By adjusting this critical parameter according to power output and load conditions, the system achieves adaptability to varying electrical demands without requiring a completely complex control architecture
3Device complexity
If a single DC-to-DC converter is used, then the device complexity is reduced, but the ability to meet increased electrical load demands deteriorates
Solution Approach 1:
The patent divides the DC-to-DC conversion function into separate primary and secondary converter modules. This segmentation allows the system to scale power output by activating additional modules when needed, meeting increased electrical load demands while keeping each individual converter module relatively simple
Solution Approach 2:
The system combines multiple DC-to-DC converter modules (primary and secondary) that can operate independently or together. By merging these modules under unified control, the system achieves higher power output capability when loads demand it, while maintaining the option to operate with fewer modules when complexity should be minimized
Data Source
AI summary
A DC-to-DC converter may be disposed in a vehicle for converting a high voltage from a power source to a low voltage. The DC-to-DC converter may include a primary converter, a secondary converter, and a DC-to-DC module. The DC-to-DC module may control the operation of the secondary converter based on a set-point threshold and a power output of the primary converter, where the set-point threshold may be variably set.