Vehicle DC-DC Power Conversion for Priority Load Backup

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Solution Overview

Problem

High-performance electric and hybrid vehicles face challenges in reducing the weight and size of their electrical systems while maintaining power delivery and ensuring safety, as existing solutions require complex and costly redundant structures to manage power distribution and handle malfunctions effectively.

Innovation Solution

An electrical system with a DC-DC electronic power converter that selectively transfers energy between high-voltage and low-voltage circuits, using a management and conversion system to keep priority loads powered during malfunctions, and includes a control unit to monitor and control power distribution, ensuring safety and reducing weight and complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the storage device of the low-voltage electric circuit is eliminated and the power of the DC-DC electronic power converter is increased, then the weight and size of the low-voltage electric circuit are reduced, but the total weight saved is modest and the manufacturing costs significantly increase

Engineering Contradiction:
Improveweight of low-voltage electric circuitVSAvoidmanufacturing cost
Core Design Contradiction:
Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent segments the electrical loads into priority loads and non-priority loads, and segments the power supply sources into first storage system and second storage system. The DC-DC electronic power converter selectively supplies power to priority loads during malfunctions, while non-priority loads are disconnected. This segmentation allows the system to maintain safety and performance for critical functions while reducing the overall power capacity requirements of the DC-DC converter, thereby reducing manufacturing costs.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements partial action by having the DC-DC electronic power converter operate at full power only during malfunction conditions to supply priority loads, rather than continuously operating at high power. During normal operation, the second storage system handles non-priority loads, allowing the DC-DC converter to operate at lower power levels. This reduces the required power rating of the DC-DC converter, thereby reducing weight savings while significantly reducing manufacturing costs.

Inventive Principle:
Principle #16Partial or excessive action

2Device complexity

If the storage device of the low-voltage electric circuit is eliminated in entirely electric vehicle, then the vehicle structure is simplified, but the DC-DC electronic power converter needs to always remain active and continuously stressed, requiring more expensive designing

Engineering Contradiction:
Improvecomplexity of electrical systemVSAvoiddesign cost of DC-DC electronic power converter
Core Design Contradiction:
Device complexityVSEase of manufacture

Solution Approach 1:

The patent segments the electrical loads into priority loads and non-priority loads, and segments the power supply sources into first storage system and second storage system. This segmentation allows the DC-DC electronic power converter to remain inactive during normal operation and only activate during malfunction conditions, significantly reducing its operating stress and extending its service life, thereby reducing design costs.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The DC-DC electronic power converter operates periodically rather than continuously - it remains inactive during normal operation and only activates during malfunction conditions. This periodic action reduces the cumulative operating hours and stress on the DC-DC converter, allowing for a less expensive design that doesn't need to withstand continuous 24/7 operation.

Inventive Principle:
Principle #19Periodic action

3Reliability

If complex and costly redundant structures are used to manage power distribution and handle malfunctions, then safety and reliability are ensured, but the weight, size, and complexity of the electrical system increase

Engineering Contradiction:
Improvesafety during malfunctionVSAvoidcomplexity of electrical system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the electrical loads into priority loads and non-priority loads, and segments the power supply sources into first storage system and second storage system. This segmentation enables a simplified control strategy where the control unit only needs to manage the switching between power sources for priority loads during malfunctions, rather than managing complex redundant structures for all loads. This reduces system complexity while ensuring safety for critical functions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent extracts and eliminates complex redundant structures by using a simple control unit that manages power distribution based on load priority and system status. Instead of implementing complex redundant power paths and switching mechanisms, the system uses a straightforward control logic that activates the DC-DC converter only when needed, thereby ensuring reliability while reducing complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

4Weight of moving object

If local storage devices are eliminated, then weight and size are reduced, but the DC-DC electronic power converter must handle higher power demands

Engineering Contradiction:
Improveweight of storage deviceVSAvoidpower of DC-DC electronic power converter
Core Design Contradiction:
Weight of moving objectVSPower

Solution Approach 1:

The patent segments the electrical loads into priority loads and non-priority loads, and segments the power supply sources into first storage system and second storage system. This segmentation allows the DC-DC electronic power converter to supply only priority loads during malfunctions rather than all loads, significantly reducing the peak power demands it must handle. Meanwhile, local storage devices (second storage system) continue to supply non-priority loads, maintaining weight and size benefits.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements partial action by having the DC-DC electronic power converter supply only priority loads during malfunction conditions, rather than all loads. This partial power transfer reduces the required power capacity of the DC-DC converter, allowing for a lighter and smaller design while still eliminating the need for local storage devices.

Inventive Principle:
Principle #16Partial or excessive action

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 effectively reduces the size and weight of the electrical system, simplifies complexity, ensures power supply to critical loads, and reduces costs by eliminating the need for local storage devices and redundant structures, while maintaining safety and performance.

Implementation Method 1

a DC-DC electronic power converter that connects the low-voltage electric circuit and the high-voltage electric circuit to one another so as to transfer electrical energy from one to the other

Methodology Applied
Scientific EffectElectrical energy conversion:

Data Source

PatentEP4299388A1Electrical system of a road vehicle provided with a DC-DC electronic power converter and related road vehicle
Publication Date: 2024.01.03 FERRARI SPA
  • EP4299388A1 patent drawingFigure 1
  • EP4299388A1 patent drawingFigure 2
  • EP4299388A1 patent drawingFigure 3

AI summary

Electrical system (7) of a road vehicle (1) comprising a high-voltage (HV) electric circuit (8) provided with a first power storage system (6) and a low-voltage (LV) electric circuit (9) provided with a second power storage system (10) and with a plurality of electrical loads (11, 30); an electronic DC-DC power management and conversion system (15), which connects the low-voltage (LV) electric circuit (9) and the high-voltage (HV) electric circuit (8) to each other so as to selectively transfer electrical energy from the high-voltage (HV) electric circuit (8) to the low-voltage (LV) electric circuit (9) and/or vice versa; the electronic system (15) comprises a control unit (21) configured to detect a malfunction (M) of the first storage system (6) and/or of the second storage system (10) and/or of at least one of the electrical loads (11, 30) and to control, depending on the malfunction (M), a conversion device (18) and a distribution unit (20) in order to ensure the supply of power to at least some priority loads (13, 31) among the electrical loads (11, 30).