Parallel DCDC Converter and Alternator Power Control

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Solution Overview

Problem

Existing power control devices may struggle to supply the required electric power to a load when the load's current demand exceeds the output limit of a DCDC converter, even with boost control.

Innovation Solution

A power control device that includes a monitoring unit to track the output current of the DCDC converter and a control unit to manage the operation of both the DCDC converter and an alternator connected in parallel. The control unit activates the alternator when the DCDC converter's output current exceeds a first threshold and deactivates it when the output current falls below a second threshold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the threshold value is raised by performing boost control, then the starting capability of the engine is improved, but the DCDC converter cannot supply sufficient current when the load requires current exceeding the output limit

Engineering Contradiction:
Improveengine starting capabilityVSAvoidcurrent supply capability
Core Design Contradiction:
ReliabilityVSPower

Solution Approach 1:

The patent combines the DCDC converter and alternator into a unified power supply system that operates in parallel. The control unit coordinates both power sources to jointly supply current to the load, merging their capabilities to overcome the individual output limit of the DCDC converter while maintaining reliable engine starting capability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The power supply system is designed with multi-functionality, where the DCDC converter handles normal power supply operations and the alternator provides supplemental power when needed. This universal design allows the system to adapt to varying load requirements, providing both engine starting capability and sustained high current supply when the load exceeds the DCDC converter's output limit.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Device complexity

If the DCDC converter operates alone with an output limit, then the system structure is simple, but the required electric power cannot be supplied when the load current exceeds the output limit

Engineering Contradiction:
Improvesystem structureVSAvoidelectric power supply capability
Core Design Contradiction:
Device complexityVSPower

Solution Approach 1:

The patent merges the DCDC converter and alternator into a coordinated power supply system. The control unit integrates both devices to operate in parallel, combining their power output capabilities. This resolution maintains relatively simple system structure while achieving the required electric power supply capability by leveraging the complementary strengths of both power sources.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12275317B2Power control device
Publication Date: 2025.04.15 TOYOTA JIDOSHA KK
  • US12275317B2 patent drawing
  • US12275317B2 patent drawing

AI summary

A power control device for controlling a power supply system, the power control device including a DCDC converter for supplying power of a battery to a load, and an alternator connected in parallel with a DCDC converter for supplying generated power to the load, the power control device including: a monitoring unit for monitoring a current output from DCDC converter to the load; and a control unit for controlling an operation of DCDC converter and the alternator, wherein the control unit controls the alternator to generate electric power when an output current of DCDC converter monitored by the monitoring unit is equal to or greater than a first threshold value, and controls the alternator not to generate electric power when an output current of DCDC converter monitored by the monitoring unit is equal to or less than a second threshold value, which is smaller than the first threshold value.