DC-DC Converter Current Ratio Plausibility Check Without Redundant Sensors

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Solution Overview

Problem

The reliability of sensor-detected measured values in DC-to-DC converters is critical for safe and reliable operation, but existing systems often require redundant sensors to ensure accuracy, which increases costs.

Innovation Solution

A control device for DC-to-DC converters that calculates two different ratios between input and output currents using different parameters, allowing for the detection of malfunctions without redundant sensors by identifying discrepancies between the calculated ratios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If redundant sensors are used to ensure measurement reliability, then the reliability of sensor-detected measured values is improved, but the device complexity and cost increase

Engineering Contradiction:
Improvereliability of sensor-detected measured valuesVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system uses its own existing sensors and operational parameters to verify measurement reliability. The control device calculates expected relationships between measured values and compares them against actual sensor readings, allowing the system to self-verify without external redundant sensors.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The control device continuously monitors the consistency between different measured values by calculating expected relationships (e.g., power balance, current ratios) and comparing them with actual sensor readings. When deviations exceed thresholds, the system triggers fault detection and can activate backup sensors or safe operating modes.

Inventive Principle:
Principle #23Feedback

2Reliability

If redundant sensors are used to ensure measurement reliability, then the reliability of sensor-detected measured values is improved, but the cost increases

Engineering Contradiction:
Improvereliability of sensor-detected measured valuesVSAvoidcost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The system uses its own existing sensors and operational parameters to verify measurement reliability. The control device calculates expected relationships between measured values and compares them against actual sensor readings, allowing the system to self-verify without external redundant sensors.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The control device continuously monitors the consistency between different measured values by calculating expected relationships (e.g., power balance, current ratios) and comparing them with actual sensor readings. When deviations exceed thresholds, the system triggers fault detection and can activate backup sensors or safe operating modes.

Inventive Principle:
Principle #23Feedback

3Reliability

If multiple calculation methods are used to verify measured values, then the reliability of control parameters is improved, but the computational complexity increases

Engineering Contradiction:
Improvereliability of control parametersVSAvoidcomputational complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system uses its own existing sensors and operational parameters to verify measurement reliability. The control device calculates expected relationships between measured values and compares them against actual sensor readings, allowing the system to self-verify without external redundant sensors.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The control device continuously monitors the consistency between different measured values by calculating expected relationships (e.g., power balance, current ratios) and comparing them with actual sensor readings. When deviations exceed thresholds, the system triggers fault detection and can activate backup sensors or safe operating modes.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS12334810B2Controller for a DC-to-DC converter, DC-to-DC converter device, and method for actuating a DC-to-DC converter
Publication Date: 2025.06.17 ROBERT BOSCH GMBH
  • US12334810B2 patent drawing
  • US12334810B2 patent drawing

AI summary

The invention relates to the verification of operating parameters, in particular input and output values of a DC-to-DC converter which are detected by a sensor. For this purpose, the ratio between the input current and the output current of a DC-to-DC converter is calculated on the basis of two different calculation methods, wherein the different calculation methods are at least partly based on different parameters. If the two calculation methods lead to the same or at least approximately the same ratio of input current to output current, a plausibility check can thus be run on the reliability of the parameters being used.