Vehicle DC/DC Converter Switching for Balanced Usage
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Solution Overview
Problem
In dual voltage architectures of heavy-duty vehicles, balancing the power supplied by multiple DC/DC converters is challenging, leading to inefficiencies in energy consumption and reduced converter lifespan.
Innovation Solution
A method and system for controlling DC/DC converters in a vehicle's electrical system, where converters alternate between active and rest states based on current ranges and cumulative operation time, ensuring only one converter is active during rest mode, and the least used converter is activated to balance usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple DC/DC converters are used in parallel to supply the second electrical network, then the power supply capacity is improved, but the balancing of power distribution among converters deteriorates
Solution Approach 1:
The control method monitors cumulative operation time of each converter in advance and uses this data to make switching decisions. By tracking usage history before activation, the system proactively balances the distribution of operational load across converters, preventing any single converter from being overused while maintaining adequate power supply capacity.
Solution Approach 2:
The system dynamically switches between multiple converters based on real-time monitoring of cumulative operation time. The converter selection is not static but adapts continuously, allowing the system to optimize power distribution dynamically. This dynamic switching ensures that converters with lower cumulative usage are activated first, automatically balancing the load distribution.
2Loss of energy
If only one DC/DC converter is activated at a time during rest mode, then the energy consumption is reduced, but the power supply capability deteriorates
Solution Approach 1:
The control method implements periodic switching between converters based on cumulative operation time thresholds. Instead of continuously operating multiple converters, the system alternates between them in periodic cycles, allowing each converter to rest after reaching a certain usage threshold. This periodic activation pattern reduces overall energy consumption while maintaining adequate power supply through sequential operation.
Solution Approach 2:
The system ensures continuous power supply to the second electrical network by maintaining a ready pool of converters that can be quickly activated. While only one converter operates at a time during rest mode to save energy, the monitoring system continuously tracks cumulative usage, enabling seamless switching between converters to maintain uninterrupted power supply capability.
3Device complexity
If converters operate without usage tracking, then the system complexity is reduced, but the converter lifespan deteriorates
Solution Approach 1:
The control method incorporates feedback mechanisms that continuously monitor and record the cumulative operation time of each converter. This feedback information is used to make informed decisions about which converter to activate next, ensuring balanced usage distribution. The feedback loop tracks usage data and feeds it back to the control logic, enabling lifespan optimization without excessive complexity.
Solution Approach 2:
Each converter's cumulative operation time is automatically tracked and recorded by the control system, eliminating the need for manual monitoring or complex external management systems. The system serves itself by automatically managing converter activation based on accumulated usage data, extending lifespan through self-regulated load distribution without adding significant complexity.
Data Source
AI summary
A method to control operation of electrical converter units in an electrical system of a vehicle comprising a first and a second electrical network, the first and the second electrical network being coupled respectively to a positive terminals of a first battery and a second battery, each converter of a plurality of converters having an active state in which the converter output supplies current to the second electrical network, and a rest state in which the converter output does not supply current to the second electrical network, each converter of the plurality of converters exhibiting a respective cumulative operation time in each of a plurality of different current ranges, wherein a single converter is active in a vehicle rest mode, and a balance of converters is carried out upon cumulative respective usage of each converter.