Dual-Converter Power Supply Control for Intermediate Current Efficiency

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Solution Overview

Problem

Existing electric power supply systems experience reduced voltage conversion efficiency in intermediate current regions due to the use of either high-voltage or low-voltage converters, and there is no effective method to prevent further deterioration of low-voltage batteries in these systems.

Innovation Solution

An electric power supply system with a high-voltage and low-voltage battery, and two converters with different rated power, controlled by a device that switches between operation modes based on current ranges to optimize efficiency and prevent low-voltage battery deterioration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If only the first converter or second converter is used depending on output current range, then voltage conversion efficiency is improved in high and low current regions, but voltage conversion efficiency cannot be avoided to be reduced in the intermediate region at the boundary

Engineering Contradiction:
Improvevoltage conversion efficiencyVSAvoidoperational complexity in intermediate region
Core Design Contradiction:
Loss of energyVSEase of operation

Solution Approach 1:

The patent divides the current output range into three distinct segments: a first current range where only the first converter operates, a second current range where only the second converter operates, and a third intermediate current range where both converters operate simultaneously. This segmentation allows the system to optimize voltage conversion efficiency in each region while providing a specific operational mode for the intermediate boundary region where both converters work together, thereby avoiding the efficiency reduction that would occur if only one converter were used alone in that region.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent merges the operation of both the first converter and the second converter in the third current range (intermediate region). By allowing both converters to operate simultaneously and coordinating their output currents, the system achieves improved voltage conversion efficiency in the boundary region where neither converter alone would be efficient, thus combining the strengths of both converters to overcome the limitation of individual operation.

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If the low-voltage battery is used to supply power to the load, then the converter operations can be simplified, but the low-voltage battery deteriorates further

Engineering Contradiction:
Improveconverter operation complexityVSAvoidlow-voltage battery durability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The control device monitors the output current value and uses this feedback to dynamically determine the appropriate operational mode. When the output current falls within the third current range (intermediate region), the control device activates a mode where both converters operate simultaneously, thereby reducing the discharge current from the low-voltage battery and minimizing its deterioration, while still meeting the load power requirements.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent changes the operational parameters of the converter system by introducing a third operational mode for the intermediate current range. In this mode, the control device adjusts the output currents of both converters based on the load requirements, thereby optimizing the power distribution to reduce stress on the low-voltage battery while maintaining system efficiency.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If both converters operate simultaneously to cover intermediate current range, then voltage conversion efficiency is improved across all regions, but the control complexity increases

Engineering Contradiction:
Improveoverall voltage conversion efficiencyVSAvoidcontrol device complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The control device is designed with segmented control logic that divides the operational space into three distinct current ranges, each with a predetermined operational mode. This segmentation simplifies the control complexity by providing clear decision boundaries: if the output current is in the first range, use only the first converter; if in the second range, use only the second converter; if in the third intermediate range, use both converters. This structured approach avoids the need for complex real-time optimization algorithms.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The control device dynamically switches between different operational modes based on the real-time output current value. This dynamic control allows the system to adapt to varying load conditions while maintaining simple control logic through predefined current ranges and corresponding operational modes, thereby achieving high overall efficiency without excessive control complexity.

Inventive Principle:
Principle #15Dynamics

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

Enhances voltage conversion efficiency across a wide range of currents and prevents further deterioration of low-voltage batteries by selectively using converters and managing battery discharge, thereby improving overall system performance.

Implementation Method 1

a first converter electrically connected between the high-voltage battery and the low-voltage battery, the first converter being configured to perform voltage conversion between the high-voltage battery and the low-voltage battery

Methodology Applied
Scientific EffectVoltage conversion: Electromagnetic Induction

Implementation Method 2

a second converter electrically connected between the high-voltage battery and the low-voltage battery, the second converter being configured to perform voltage conversion between the high-voltage battery and the low-voltage battery

Methodology Applied
Scientific EffectVoltage conversion: Electromagnetic Induction

Data Source

PatentUS20250330027A1Electric power supply system
Publication Date: 2025.10.23 TOYOTA JIDOSHA KK
  • US20250330027A1 patent drawing
  • US20250330027A1 patent drawing
  • US20250330027A1 patent drawing

AI summary

An electric power supply system includes: a high-voltage battery; a low-voltage battery having a nominal voltage lower than that of the high-voltage battery, the low-voltage battery being electrically connected to a load; a first converter electrically connected between the high-voltage battery and the low-voltage battery, the first converter being configured to perform voltage conversion between the high-voltage battery and the low-voltage battery; a second converter electrically connected between the high-voltage battery and the low-voltage battery, the second converter being configured to perform voltage conversion between the high-voltage battery and the low-voltage battery, the second converter having rated electric power lower than that of the first converter; and a control device that controls operations of the first converter and the second converter. The control device can selectively execute a plurality of operation modes depending on a total value of output currents of the first converter and the second converter.