Dual Active Bridge DC/DC Converter With Multi-Frequency Switching
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Solution Overview
Problem
Existing DC/DC converters in electric vehicles face challenges in efficiently converting high-voltage to low-voltage and vice versa, requiring bulky and expensive components, and lack a common solution that balances robustness, size, weight, and cost optimization across various automotive applications.
Innovation Solution
A power conversion device utilizing a transformer with a microcontroller that operates at multiple frequencies to selectively switch switches on both sides of the transformer, employing a dual active bridge topology that reduces component stress and cost by using a single printed circuit board and digital processing for energy transfer control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional DC/DC converter topologies are used, then voltage conversion is achieved, but the device size and cost increase due to bulky components
Solution Approach 1:
The patent employs dynamic frequency switching where the converter operates at a first frequency for power conversion and a second frequency for demagnetization. This dynamic operation allows the use of smaller magnetic components while maintaining conversion capability, resolving the contradiction between power conversion and device size.
Solution Approach 2:
The invention changes the operating frequency parameter dynamically - operating at a higher first frequency during power conversion and switching to a lower second frequency during demagnetization phases. This parameter variation enables reduced component size while preserving the voltage conversion function.
2Reliability
If robust DC/DC converter design is implemented, then reliability improves, but cost and complexity increase
Solution Approach 1:
The patent combines the power conversion function and demagnetization function into a single integrated operating cycle. By merging these functions and coordinating them through unified control, the design achieves robustness without proportionally increasing complexity.
Solution Approach 2:
The invention uses periodic switching between two frequency states - a first frequency for power transfer and a second frequency for demagnetization. This periodic action pattern provides reliable operation through controlled cycles while maintaining manageable control complexity.
3Speed
If high-frequency switching is used, then dynamic response improves, but component stress increases
Solution Approach 1:
The patent dynamically adjusts the switching frequency based on operational requirements - using a higher first frequency when rapid response is needed and switching to a lower second frequency during demagnetization to reduce stress. This dynamic adaptation resolves the contradiction between response speed and component stress.
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 solution provides stable, efficient, and scalable energy conversion across different voltage ranges, reducing component stress and cost while improving dynamic response and adaptability to various system requirements, making it suitable for a wide range of automotive applications.
Implementation Method 1
The transformer includes a primary side and a secondary side... selectively switch a first plurality of switches on the primary side and a second plurality of switches on the secondary side to convert a first input signal into a first output signal
Data Source
AI summary
In at least one embodiment, a power conversion device for a vehicle is provided. The power conversion device includes a transformer, a microcontroller, and a control circuit. The microcontroller is configured to operate at a first frequency to receive a first current signal indicative of a current of a first voltage network and to generate a first envelope control signal in response to the first current signal. The controller is configured to selectively switch a first plurality of switches on a primary side and a second plurality of switches on a secondary side to convert a first input signal into first output signal in response to at least the first envelope control signal. The controller is further configured to selectively switch the first plurality of switches and the second plurality of switches at a second frequency that is greater than the first frequency.