Vehicle DC/DC Converter Switching for Key-Off Load Management

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Solution Overview

Problem

Existing electric vehicles face reduced driving range due to continued power consumption from AC and DC outlets after a key-off condition, which depletes the traction battery's limited storage capacity.

Innovation Solution

Implementing a first and second DC/DC converter with different power output capacities, controlled by executable instructions to activate or deactivate based on operating conditions, managing power distribution efficiently to conserve battery charge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the vehicle provides AC and DC power outlets that remain active after key-off to allow user access to power, then user convenience is improved, but the traction battery's limited storage capacity is depleted faster, reducing driving range

Engineering Contradiction:
Improveuser access to power outletsVSAvoidtraction battery power consumption
Core Design Contradiction:
Ease of operationVSUse of energy by moving object

Solution Approach 1:

The patent segments the DC/DC converter functionality into multiple capacity modes (first capacity and second capacity). The controller selectively activates either a first DC/DC converter or a second DC/DC converter based on operating conditions, allowing the system to provide power outlet functionality while consuming less battery power by using only the necessary capacity level.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic capacity adjustment where the DC/DC converter can operate at different capacity levels. The controller dynamically switches between first and second capacity modes based on whether the vehicle is in motion or stationary, ensuring the power conversion system adapts its power output to match actual user needs and vehicle state.

Inventive Principle:
Principle #15Dynamics

2Power

If the vehicle uses a single high-capacity DC/DC converter to ensure sufficient power output for all accessories, then power availability is improved, but device complexity and power management overhead increase

Engineering Contradiction:
Improvepower output capacityVSAvoidpower management system complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

Instead of using a single high-capacity DC/DC converter, the patent segments the power conversion function into multiple converters with different capacity levels. This allows the system to use a lower-capacity converter during normal operation and only engage the higher-capacity converter when maximum power is needed, reducing overall system complexity and power management burden.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent extracts the high-capacity power conversion function into a separate, optional component (the second DC/DC converter). This allows the base system to operate with simpler, lower-capacity converters, and the high-capacity converter is only activated when specifically needed, effectively removing unnecessary complexity from the normal operating configuration.

Inventive Principle:
Principle #2Taking out (Extraction)

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

This approach reduces power consumption after a key-off event, maintains vehicle range by optimizing power usage for accessories, and enhances electric power distribution efficiency.

Implementation Method 1

The electric power that is provided by the power source may be converted by an inverter to generate AC power that is supplied to the AC power outlets and the DC power may be provided via a DC/DC converter

Methodology Applied
Scientific EffectElectrical Energy Transformation:

Data Source

PatentUS20250313091A1Methods and system for managing key-off electric load
Publication Date: 2025.10.09 FORD GLOBAL TECH LLC
  • US20250313091A1 patent drawing
  • US20250313091A1 patent drawing
  • US20250313091A1 patent drawing

AI summary

Systems and methods for operating a vehicle power system are described. The vehicle power system includes a lower voltage battery and a power distribution system. Power supplied to the power distribution system may be switched from one source to another source based on an estimated electrical load.