DC-DC Converter Phase Control for Long-Distance Vehicle Power Transfer
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Solution Overview
Problem
Existing systems for controlling direct-current to direct-current converters in vehicle implements are inefficient in managing voltage levels and power transfer between the primary and secondary converters, particularly in off-road vehicles with extended distances and varying load requirements.
Innovation Solution
A system comprising a primary converter and multiple secondary converters, each with synchronized semiconductor switches and controllers, utilizing transformers and inductances to manage voltage levels and power transfer efficiently, with phase detection and control signals to adjust phase offsets for optimal energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a direct-current to direct-current converter is used to support voltage conversion in vehicle implements, then voltage level conversion is enabled, but power loss increases over extended distances
Solution Approach 1:
The patent introduces an alternating current (AC) intermediary signal between the primary and secondary direct current (DC) converters. The primary converter transforms DC to AC, which can be efficiently transmitted over extended distances through transformers, and then converted back to DC by secondary converters. This AC intermediary enables efficient power transfer over long distances while minimizing power loss, as AC transmission allows for voltage transformation and impedance matching that reduces resistive losses.
Solution Approach 2:
The system dynamically changes electrical parameters including voltage level, current frequency, and phase angle to optimize power transfer. By converting DC to AC with variable frequency and voltage, the system can adapt to different transmission distances and load requirements, minimizing power loss through optimal parameter selection at each stage of conversion and transmission.
2Adaptability or versatility
If multiple secondary converters are used to support various load requirements, then adaptability improves, but system complexity increases
Solution Approach 1:
The patent divides the power conversion system into one primary DC-AC converter and multiple secondary DC-DC converters, each serving specific load requirements. This segmentation allows independent optimization of each converter for its specific function while sharing common control architecture and synchronization mechanisms, reducing overall system complexity compared to having one large complex converter handling all loads.
Solution Approach 2:
The secondary converters are designed with universal control characteristics that allow them to serve multiple load types and voltage requirements. By implementing standardized interfaces and common control algorithms across all secondary converters, the system achieves high adaptability to various load requirements while maintaining manageable complexity through reuse of proven design modules and control strategies.
3Productivity
If phase offset control is implemented for synchronized semiconductor switches, then power transfer efficiency improves, but control system complexity increases
Solution Approach 1:
The control system implements feedback mechanisms that monitor the phase relationship between primary and secondary converters and automatically adjust phase offsets to maintain optimal power transfer. This closed-loop control ensures high efficiency by continuously adapting to changing operating conditions while using proven control algorithms that balance sophistication with implementation feasibility, avoiding excessive complexity.
Solution Approach 2:
The system pre-calculates and establishes appropriate phase offsets based on anticipated operating conditions and load requirements. By preparing control parameters in advance and using predetermined synchronization strategies, the system achieves high power transfer efficiency without requiring complex real-time calculations, thereby reducing control system complexity while maintaining productivity.
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
Enables efficient voltage regulation and power transfer over extended distances in off-road vehicles, supporting various load requirements and minimizing power loss through synchronized phase control and impedance management.
Implementation Method 1
A primary converter has primary semiconductor switches. A primary controller provides control signals to the primary semiconductor switches. The primary converter provides an alternating current (AC) signal... Each secondary converter has secondary semiconductor switches... Each transformer provides an intermediate interface (for the AC signal) between the primary converter and a secondary converter
Data Source
Figure 1
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Figure 3A
AI summary
Each one of the secondary converters has a corresponding transformer having a primary winding associated with a primary alternating current (AC) signal and a secondary winding associated with a secondary alternating current (AC) signal. A secondary controller provides secondary control signals to the secondary semiconductor switches of the secondary converters with one or more time-synchronized, target phase offsets with respect to an observed phase of the alternating current signal (e.g., primary alternating current signal or the secondary alternating current signal) to provide the target phase offset (or targeted phase offsets) commensurate with or sufficient to support a required electrical energy transfer from the primary controller to the corresponding secondary controller (or secondary controllers).