DC-DC Converter Control for Connector Miscoupling Detection
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Solution Overview
Problem
In electrified vehicles, such as fuel cell electric vehicles, miscoupling of connectors between DC-DC converters can lead to failure, as existing systems lack efficient detection and response mechanisms, potentially causing operational failures during power exchange between the fuel cell and high-voltage battery.
Innovation Solution
A DC-DC converter system with a converter controller that determines miscoupling by comparing actual voltage to a voltage command, transmitting error signals, and performing shutdown operations when miscoupling is detected, incorporating a transformation circuit with inductors and switching elements for efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a DC-DC converter is operated without connector coupling detection, then the device complexity is reduced, but the reliability deteriorates due to potential miscoupling failures
Solution Approach 1:
The patent implements a feedback mechanism where the converter controller continuously monitors the voltage at the first DC terminal and compares it with the received voltage command. This closed-loop feedback allows the system to detect connector miscoupling by identifying deviations between expected and actual voltage values, thereby improving reliability without requiring complex additional detection hardware.
Solution Approach 2:
The DC-DC converter performs self-diagnosis by using its own operational parameters (voltage command and actual voltage) to detect connector coupling status. The converter controller independently determines whether the connector is properly coupled by analyzing the relationship between the voltage command from the external controller and the actual voltage at the terminal, eliminating the need for separate detection devices.
2Reliability
If connector miscoupling is detected through voltage comparison, then the reliability is improved, but the measurement precision requirement increases
Solution Approach 1:
The patent introduces the voltage command as an intermediary reference value that mediates between the expected voltage and actual voltage measurement. By comparing the actual voltage at the first DC terminal with the voltage command received from the external controller, the system can detect miscoupling through relative comparison rather than requiring absolute precision, thereby reducing the stringent requirements for measurement precision while maintaining detection reliability.
3Reliability
If the converter performs shutdown operation upon detecting miscoupling, then the reliability is improved, but the productivity decreases due to operational interruptions
Solution Approach 1:
The patent applies preliminary anti-action by implementing a shutdown operation that prevents potential damage before it occurs. When the converter controller detects connector miscoupling through voltage comparison, it immediately initiates a shutdown sequence that stops power conversion and isolates the converter from the electrical system. This preemptive action protects the converter and connected devices from damage that would certainly occur if operation continued with miscoupled connectors.
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 system efficiently detects and responds to connector miscoupling, preventing operational failures by determining voltage mismatches and initiating shutdowns, thus protecting the DC-DC converter and connected devices.
Implementation Method 1
a transformation circuit connected to the first DC terminal and a second DC terminal while being located therebetween
Data Source
AI summary
A direct current to direct current (DC-DC) converter, a vehicle including the converter, and a controlling method thereof are proposed. The DC-DC converter is capable of efficiently detecting and responding to miscoupling of a connector. The DC-DC converter includes a first inlet corresponding to a first DC terminal, a transformation circuit connected to the first DC terminal and a second DC terminal while being located therebetween, and a converter controller, wherein when receiving a voltage command corresponding to the first DC terminal from an external controller, the converter controller is configured to determine whether or not a connector coupled to the first inlet is miscoupled thereto based on whether or not a voltage of the first DC terminal follows the voltage command.