DC-DC Converter Current Limiting for Input Voltage Stability

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Solution Overview

Problem

Existing DC-DC converters in electric vehicles can cause voltage drops on the input side, affecting the functionality of connected consumers due to excessive power demand during charging processes, particularly when charging link capacitors.

Innovation Solution

A control apparatus for DC-DC converters that combines voltage regulation with current regulation, adjusting the maximum permissible current based on input voltage levels to prevent overloading and maintain stable voltage levels, using a monitoring device to ensure reliable operation of connected consumers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the DC-DC converter charges the link capacitor from the low-voltage battery, then the link capacitor voltage is restored to enable power converter operation, but the low-voltage battery is over-stressed causing voltage drop that affects consumer functionality

Engineering Contradiction:
Improvelink capacitor charging reliabilityVSAvoidinput voltage drop affecting consumers
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The control system dynamically switches between voltage control mode and current control mode based on real-time monitoring of input voltage levels. When input voltage remains above a threshold, voltage control mode operates to efficiently charge the link capacitor. When input voltage drops below the threshold, the system transitions to current control mode with a reduced current ceiling to prevent further voltage degradation, thereby maintaining reliability of both the charging process and connected consumers.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control apparatus changes the current control parameter (current ceiling) based on the input voltage state. In normal conditions, the system allows higher current to quickly restore the link capacitor. When voltage drop is detected, the system reduces the current ceiling to a lower value, effectively adapting the charging parameters to prevent over-stressing the low-voltage battery and maintain stable operation of connected consumers.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If high current is used to charge the link capacitor quickly, then the charging time is reduced, but the input voltage drops excessively affecting the operation of other consumers

Engineering Contradiction:
Improvelink capacitor charging speedVSAvoidconsumer operation stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The control system dynamically adjusts the current ceiling based on real-time input voltage monitoring. During normal charging when input voltage is sufficient, the system operates at high current to maximize charging speed. When input voltage drops below the threshold, the system automatically reduces the current ceiling to prevent excessive voltage drop, thereby maintaining the stability of connected consumers while continuing the charging process at a reduced rate.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control apparatus continuously monitors the input voltage and periodically adjusts the current control mode accordingly. This periodic monitoring and adjustment ensures that the system can respond to changing voltage conditions, switching between high-current charging mode and limited-current mode to balance charging speed with consumer operation stability.

Inventive Principle:
Principle #19Periodic action

Data Source

PatentUS20250222804A1Control apparatus for a DC-DC converter and method for actuating a DC-DC converter
Publication Date: 2025.07.10 ROBERT BOSCH GMBH
  • US20250222804A1 patent drawing
  • US20250222804A1 patent drawing

AI summary

The invention relates to the actuation of a DC-DC converter. A control variable of the DC-DC converter is formed as a combination of voltage regulation and current regulation. Thereby the maximum permissible current for the current regulation can be adjusted as a function of a momentary value of the input voltage on the DC-DC converter.