DC-DC Converter Protection Circuit for Connection Error
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Solution Overview
Problem
Electric vehicles face risks of short-circuit and system failure due to erroneous battery connections, which existing methods address by using fuses that shut off power but are costly and require replacement, and do not allow for immediate reactivation.
Innovation Solution
A DC-DC converter with a protection circuit that includes MOS-FETs to detect and prevent current flow when battery connections are erroneous, using first and second protection elements to control the current path between high and low voltage batteries, preventing short circuits without the need for fuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is used to shut off the circuit in case of over-current, then the circuit can be protected from short-circuit damage, but the vehicle cannot be reactivated before exchanging the converter and lots of cost is spent on the expensive fuse component
Solution Approach 1:
The patent applies the dynamics principle by using controllable switching elements (MOS-FETs Q1 and Q2) that can dynamically change their state between conducting and blocking based on control signals. Unlike a static fuse that permanently opens the circuit, these switches can be turned on or off by the control unit (310) depending on whether an error condition is detected, enabling the system to be reactivated after error correction without component replacement
Solution Approach 2:
The patent implements feedback by having the control unit (310) continuously monitor the connection status of terminals T1+ and T2+ and adjust the state of switching elements Q1 and Q2 accordingly. When an erroneous connection is detected, the control unit activates the protection circuit to block current flow; when the connection is corrected, the control unit deactivates the protection, allowing normal operation to resume. This closed-loop feedback mechanism enables automatic reactivation without manual intervention or component replacement
2Reliability
If a fuse is used to shut off the circuit in case of over-current, then the circuit can be protected from short-circuit damage, but lots of cost is spent on the expensive fuse component and post-processing
Solution Approach 1:
The patent replaces the mechanical fuse system with an electronic protection circuit based on MOS-FETs (Q1, Q2) and control logic (310). This substitution eliminates the need for expensive replaceable fuse components while providing the same short-circuit protection function. The electronic switches can be controlled to open or close the circuit based on detected error conditions, providing a more cost-effective and integrated solution
Solution Approach 2:
The protection circuit integrates multiple functions into a single system: it provides over-current protection, connection error detection, and automatic circuit control all through the same switching elements and control unit. This multi-functional approach eliminates the need for separate fuse components and reduces overall system cost while maintaining comprehensive protection capabilities
3Ease of operation
If protection circuit with MOS-FETs is used to control current path, then short-circuit can be prevented without fuses and vehicle can be reactivated immediately, but device complexity increases
Solution Approach 1:
The patent divides the protection function into distinct modular components: switching element Q1 for the high voltage battery connection, switching element Q2 for the low voltage battery connection, and a control unit (310) that manages both switches. This segmentation allows each component to have a specific, simple function while the overall system achieves sophisticated protection and reactivation capabilities. The modular structure makes the complexity manageable and the individual components relatively simple
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
The protection circuit effectively prevents short circuits during erroneous connections, allowing for safe and cost-effective operation by eliminating the need for fuses and enabling immediate reactivation of the vehicle system.
Implementation Method 1
A DC-DC converter with a protection circuit for a connection error which is connected to a high voltage battery and a low voltage battery to convert a high voltage of the high voltage battery into a low voltage to charge the low voltage battery, including: a connecting unit which connects the high voltage battery and the low voltage battery; a converting unit which converts a high voltage supplied from the high voltage battery into a low voltage to charge the low voltage battery; and a protection circuit which is located between the connecting unit and the converting unit and is turned off when at least one of the high voltage battery and the low voltage battery is erroneously connected
Data Source
AI summary
The present invention provides a DC-DC converter which is connected to a high voltage battery and a low voltage battery to convert a high voltage of the high voltage battery into a low voltage to charge the low voltage battery, including: a connecting unit which connects the high voltage battery and the low voltage battery; a converting unit which converts a high voltage supplied from the high voltage battery into a low voltage to charge the low voltage battery; and a protection circuit which is located between the connecting unit and the converting unit and is turned off when at least one of the high voltage battery and the low voltage battery is erroneously connected, to shut off a current path between the high voltage battery and the low voltage battery.