Distributed DCDC Converter Control for EV Battery Power Demand

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Solution Overview

Problem

Current electric vehicle (EV) technologies face challenges in optimizing the control of direct current to direct current (DCDC) converters to efficiently supply power to the electrical systems of EVs.

Innovation Solution

The implementation of a smartcell battery system that employs a distributed system of DCDC converters, where each converter is connected to a battery cell cluster and controlled by a master controller based on monitored power demands, allowing for dynamic activation and deactivation of converters to optimize power supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple DCDC converters are used to supply power to the electrical system, then the power supply capacity is improved, but the system complexity and energy losses increase

Engineering Contradiction:
Improvepower supply capacityVSAvoidsystem complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The battery system is divided into multiple independent battery cell clusters, each with its own DCDC converter. This segmentation allows the system to scale power capacity by activating only the necessary number of converters, rather than requiring all converters to operate simultaneously, thus managing system complexity while providing high power capacity when needed.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system dynamically controls the activation and deactivation of individual DCDC converters based on real-time power demands of the electrical system. This dynamic control allows the system to adapt its complexity level to the actual power requirements, maintaining simplicity when low power is needed and providing full capacity when high power is required.

Inventive Principle:
Principle #15Dynamics

2Power

If multiple DCDC converters operate simultaneously to meet power demand, then the power supply capacity is improved, but the energy losses increase

Engineering Contradiction:
Improvepower supply capacityVSAvoidenergy losses
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

Instead of operating all DCDC converters simultaneously, the system activates only the partial number of converters necessary to meet the current power demand. This partial action approach reduces the total energy consumption and associated losses while still providing sufficient power capacity to satisfy the electrical system's requirements.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The system converts the potential harm of having multiple converters (which would increase losses if all operated continuously) into a benefit by using selective activation. The ability to choose which converters to activate allows the system to minimize energy losses while maintaining the power supply capacity advantage of having multiple converters available.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Use of energy by moving object

If a distributed system of DCDC converters is implemented, then the efficiency is improved through selective activation, but the control complexity increases

Engineering Contradiction:
Improveenergy efficiencyVSAvoidcontrol complexity
Core Design Contradiction:
Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The master controller continuously monitors the power demands of the electrical system and uses this feedback information to determine which DCDC converters should be activated. This feedback mechanism enables the system to automatically optimize energy efficiency by matching converter activation to actual power needs, managing control complexity through a straightforward monitor-and-respond approach.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The master controller serves multiple functions: it monitors power demands, determines activation requirements, and controls the switching of multiple DCDC converters. This multi-functionality consolidates control complexity into a single controller rather than requiring distributed intelligence across all converters, improving energy efficiency while managing control complexity centrally.

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

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

This approach enhances the efficiency and performance of EVs by ensuring that only the necessary DCDC converters are active, operating under high loads, which optimizes energy usage and reduces losses.

Implementation Method 1

direct current to direct current (DCDC) converters

Methodology Applied
Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentUS20250065773A1Control strategy for a distributed system of DCDC converters
Publication Date: 2025.02.27 VOLVO CAR CORP
  • US20250065773A1 patent drawing
  • US20250065773A1 patent drawing
  • US20250065773A1 patent drawing

AI summary

Techniques for optimized control of a distributed system of direct current to direct current (DCDC) converters are described. In an example, a method comprises employing, by a system operatively coupled to at least one processor, a smartcell battery system to supply power to an electrical system of an electric vehicle, the smartcell battery system comprising a plurality of battery cell clusters arranged in three strings, each battery cell cluster of the plurality comprising one or more battery cells, DCDC converters connected to respective ones of the battery cell clusters and the electrical system. The method further comprises controlling, by the system, when respective ones of the DCDC converters activate and deactivate generation and provision of respective output voltages to the electrical system using respective ones of the battery cell clusters to which they are connected based on monitored power demands of the electrical system.