Dual-Converter Control Power Supply for Low-Power Electric Working Machines
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Solution Overview
Problem
Existing electric working machines face challenges in reducing power consumption, especially when transitioning to a low power operation state, due to the high power consumption of switching regulators and the inability to effectively manage power conversion losses in control power sources.
Innovation Solution
The electric working machine incorporates a control power source with dual converters that switch between operation states based on the controller's operation state, stopping the first converter in low power mode to reduce overall power consumption, and using a second converter to supply power efficiently, while maintaining constant voltage to the controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a linear regulator is used as the control power source, then power consumption is reduced at low power, but power loss increases when battery voltage increases
Solution Approach 1:
The patent applies dynamics by making the control power source configuration changeable based on operating conditions. The system dynamically switches between linear regulator mode and switching regulator mode depending on whether the controller is in active or sleep state, and depending on battery voltage levels. This dynamic reconfiguration allows the system to optimize the trade-off between power consumption and power loss in real-time.
Solution Approach 2:
The patent changes the operating parameters of the control power source by switching between different regulator types and modes. Specifically, it changes the conversion ratio and operating state of the switching regulator, and the regulation mode of the linear regulator, based on the controller's operation state and battery voltage. This parameter adjustment resolves the contradiction by adapting the power source characteristics to match the actual power requirements.
2Loss of energy
If a switching regulator is used as the control power source, then voltage conversion efficiency is improved, but operation current increases making it difficult to reduce overall power consumption
Solution Approach 1:
The patent segments the control power source into two distinct parts: a switching regulator and a linear regulator. The switching regulator handles the bulk of power conversion when high current is needed, while the linear regulator takes over when low current is sufficient. This segmentation allows each regulator type to operate in its optimal efficiency range, resolving the contradiction between conversion efficiency and operation current.
Solution Approach 2:
The patent applies partial action by using the switching regulator only when necessary (when the controller is active and high current is required). When the controller enters sleep mode, the system uses only the linear regulator with reduced current. This partial utilization of the high-efficiency but high-current switching regulator resolves the contradiction by limiting its operation to only when its efficiency benefits outweigh its current consumption drawbacks.
3Use of energy by moving object
If power supply from the control power source is interrupted to reduce power consumption, then battery overdischarge is suppressed, but communication availability and response time deteriorate
Solution Approach 1:
The patent implements periodic action by transitioning the controller between active and sleep states based on operational requirements. The controller periodically enters sleep mode to reduce power consumption while maintaining the ability to wake up and restore full functionality. This periodic cycling allows the system to balance power savings with operational reliability, as communications can resume when needed despite intermittent sleep periods.
Solution Approach 2:
The system performs preliminary action by maintaining a low-power standby state rather than complete power interruption. The controller remains in a sleep state with minimal power consumption but retains the capability to quickly wake up and resume communications. This preliminary maintenance of operational readiness resolves the contradiction by avoiding complete power shutdown while still achieving significant power savings.
4Use of energy by moving object
If the controller transitions to sleep mode to reduce power consumption, then battery drain is reduced, but power consumption in the control power source cannot be reduced
Solution Approach 1:
The patent extracts the control power source consumption issue from the controller power consumption problem. By separately addressing the control power source through dual regulator configuration, the system ensures that when the controller sleeps, the control power source also reduces its consumption by switching to linear regulator mode. This extraction and separate handling of the power source issue resolves the contradiction by decoupling controller state from power source state.
Solution Approach 2:
The system uses feedback from the controller's operation state to control the power source configuration. When the controller enters sleep mode, this state is detected and feeds back to the power source management system, which then switches the control power source to linear regulator mode. This feedback mechanism ensures that control power source consumption is reduced in response to controller sleep state, resolving the contradiction between controller and power source power consumption.
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 effectively reduces power consumption in both the controller and the control power source when the machine is not in use, by transitioning to a low power operation state and managing power conversion efficiently, thereby minimizing energy loss.
Implementation Method 1
a first converter 65 that converts the power supply voltage to a first control voltage, and a second converter 71 that converts the first control voltage to a second control voltage
Data Source
AI summary
An electric working machine in one aspect of the present disclosure includes a driving device, a controller, a control power source, and an operation state determiner. The control power source includes a first converter and a second converter. The control power source transitions to a first conversion state when the operation state determiner determines that the controller is in a control operation state. The control power source in the first conversion state supplies a first control current to the controller. The control power source transitions to a second conversion state when the operation state determiner determines that the controller is in a low power operation state. The control power source in the second conversion state (i) stops operation of the first converter, and (ii) supplies a second control current to the controller.