DC-DC Converter Feedforward Control for Output Ripple Reduction

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Solution Overview

Problem

DC-DC converters face significant electrical interference and current ripple on the output side, particularly due to consumers connected to the low-voltage power supply system, which can cause operational faults and damage to connected assemblies.

Innovation Solution

A control device comprising a voltage regulator and a feedforward control device that generates two controlled variables, where the dynamic response of the feedforward control system is adapted based on the electrical current, effectively counteracting current ripple by adjusting the dependency of the second controlled variable on input voltage and setpoint voltage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a DC-DC converter transmits electrical energy from high-voltage to low-voltage power supply systems, then electrical energy transmission is achieved, but electrical interference and current ripple occur on the output side

Engineering Contradiction:
Improveelectrical energy transmissionVSAvoidelectrical interference and current ripple
Core Design Contradiction:
PowerVSObject-affected harmful factors

Solution Approach 1:

The control device is divided into two independent control paths: a voltage regulator for voltage control and a feedforward control device for current control. This segmentation allows each controller to independently address its specific function, with the feedforward controller specifically targeting current ripple reduction while the voltage regulator maintains output voltage stability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The feedforward control device determines the control variable for the DC-DC converter based on the electrical current in advance, before the current ripple affects the output. By calculating the required control action ahead of time based on predicted current conditions, the system can counteract current ripple proactively rather than reactively.

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If consumers are connected to the low-voltage power supply system on the output side, then power supply functionality is provided, but operational faults and damage to connected assemblies can occur

Engineering Contradiction:
Improvepower supply functionalityVSAvoidoperational reliability of connected assemblies
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The control device continuously monitors the electrical current in the DC-DC converter and uses this feedback to dynamically adjust the control variable through the feedforward control device. This closed-loop feedback mechanism ensures that current ripple is continuously detected and corrected, protecting connected consumers from harmful current fluctuations while maintaining continuous power supply functionality.

Inventive Principle:
Principle #23Feedback

3Stability of the object's composition

If a voltage regulator is used for closed-loop control of the DC-DC converter, then output voltage stability is achieved, but current ripple on the output side is not sufficiently reduced

Engineering Contradiction:
Improveoutput voltage stabilityVSAvoidcurrent ripple
Core Design Contradiction:
Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The control device merges two separate control mechanisms: the voltage regulator for maintaining output voltage stability and the feedforward control device for reducing current ripple. By combining these two control functions into a unified control system that processes both voltage and current information, the system achieves both voltage stability and current ripple reduction simultaneously.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS11876442B2Control device for a DC-DC converter, DC-DC converter and method for the closed-loop control of a DC-DC converter
Publication Date: 2024.01.16 ROBERT BOSCH GMBH
  • US11876442B2 patent drawing
  • US11876442B2 patent drawing
  • US11876442B2 patent drawing

AI summary

The present invention relates to advanced control for a DC-to-DC converter. For this purpose, in the determination of a controlled variable for the control of the DC-to-DC converter, the control dynamics are adjusted according to an electric current through the DC-to-DC converter. In particular, it is possible to determine the controlled variable from a combination of a first controlled variable of a voltage controller and a second controlled variable of a feedforward control. In particular, the control dynamics of the feedforward control can be adjusted according to the electric current through the DC-to-DC converter. By adjusting the control dynamics according to current, it is possible to minimize possible current ripple on the output side.