DC Intermediate Circuit Phase and Voltage Adaptation

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Solution Overview

Problem

Electric vehicles face limited range and long charging processes due to power loss in electrical systems, which requires additional energy for cooling, necessitating a reduction in losses to enhance efficiency and range.

Innovation Solution

An intermediate circuit adaptation device with a DC intermediate circuit and a control unit that adjusts voltage and number of phases based on the current or expected operating point to minimize losses, employing multiple parallel phases and a voltage sensor for dynamic and efficient power management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple parallel phases are used to enable flexible scaling and reduce component size, then system flexibility and scalability are improved, but device complexity increases

Engineering Contradiction:
Improvesystem scalabilityVSAvoidnumber of phases
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies dynamics by enabling the number of phases to be changed based on the current operating point. The control unit can adaptively switch between different phase configurations (e.g., single-phase, two-phase, three-phase) depending on power requirements, allowing the system to scale flexibly while avoiding unnecessary complexity when full multi-phase operation is not needed.

Inventive Principle:
Principle #15Dynamics

2Loss of energy

If the intermediate circuit voltage is reduced to minimize voltage-dependent losses, then voltage-dependent losses are reduced, but the ability to meet minimum voltage requirements of loads may be compromised

Engineering Contradiction:
Improvevoltage-dependent lossesVSAvoidminimum voltage requirement compliance
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The patent applies feedback by continuously monitoring the operating conditions and adjusting the intermediate circuit voltage accordingly. The control unit uses information about the current operating point, load requirements, and power losses to make informed decisions about voltage adjustment, ensuring that minimum voltage requirements are met while optimizing efficiency.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS11518251B2Device and method for adapting a direct current intermediate circuit by varying the voltage and adapting the phase number of a DC/DC converter
Publication Date: 2022.12.06 SCHAEFFLER TECHNOLOGIES AG & CO KG
  • US11518251B2 patent drawing
  • US11518251B2 patent drawing
  • US11518251B2 patent drawing

AI summary

An intermediate circuit adaptation device for a vehicle. The intermediate circuit adaptation device includes a DC intermediate circuit with at least two phases and a control unit. The control unit is configured to change the intermediate circuit voltage and/or the number of phases of the intermediate circuit on the basis of the current operating point.