Dual DC-DC Converter Redundancy for EV Low-Voltage Power

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Solution Overview

Problem

The DC-DC converter in electric vehicles is more stressed and complex due to its operational requirements in both charging and driving scenarios, leading to a higher risk of failure, which can disrupt low voltage system functions, especially when the low voltage battery is low.

Innovation Solution

A converter system with two electrically separated high voltage DC-DC modules and a controller to manage power distribution, ensuring redundancy and fail-safe operation by switching to a functional module in case of failure, and incorporating low power DC-DC modules for non-operating modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single DC-DC converter is used to transfer power from high voltage to low voltage system, then the device complexity is reduced, but the reliability deteriorates due to higher stress and single point of failure risk

Engineering Contradiction:
ImprovereliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The single DC-DC converter is divided into two separate DC-DC converters (first and second converters) with different topologies. Each converter handles power conversion independently, so that a failure in one converter does not affect the other. This segmentation reduces the single point of failure risk while distributing the operational stress across multiple units with different design characteristics.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each DC-DC converter is designed with different local qualities (topologies) to suit specific operational requirements. The first converter may be optimized for charging scenarios while the second converter is optimized for driving scenarios. This allows each converter to have specialized characteristics that reduce stress under specific conditions, thereby improving overall reliability without requiring a single complex universal design.

Inventive Principle:
Principle #3Local quality

2Adaptability or versatility

If the DC-DC converter operates under both charging and driving scenarios, then the adaptability is improved, but the reliability deteriorates due to increased operational stress

Engineering Contradiction:
ImproveadaptabilityVSAvoidreliability
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The operational scenarios are segmented and assigned to different converters. The first DC-DC converter is primarily used during charging scenarios while the second converter is primarily used during driving scenarios. This segmentation allows each converter to be optimized for its specific scenario, reducing the stress each converter experiences while maintaining the system's adaptability to handle both charging and driving operations.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

While the converters are specialized for different scenarios, the system as a whole achieves universality by having multiple converters that can handle different operational modes. The controller manages scenario-based switching between converters, ensuring that the system can adapt to both charging and driving scenarios with appropriate converter selection, thereby maintaining versatility without over-stressing any single converter.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the DC-DC converter is designed with complex features to handle all scenarios, then the adaptability is improved, but the device complexity increases

Engineering Contradiction:
ImproveadaptabilityVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of creating a single complex converter that handles all scenarios, the system segments the functionality into two simpler converters with different topologies. Each converter is designed with simpler, scenario-specific features rather than attempting to incorporate all possible features into one unit. This segmentation reduces the device complexity of individual converters while maintaining overall system adaptability through scenario-based switching.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system achieves universality at the system level rather than at the component level. Each converter has specialized functionality for specific scenarios, but the combination of multiple converters with the controller provides universal coverage for all operational scenarios. This approach avoids the complexity of designing a single multi-functional converter while still achieving the goal of handling diverse scenarios.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS12508927B2Converter system for transferring power
Publication Date: 2025.12.30 VOLVO CAR CORP
  • US12508927B2 patent drawing
  • US12508927B2 patent drawing
  • US12508927B2 patent drawing

AI summary

A converter system for transferring power, including a first high voltage DC-DC module, a second high voltage DC-DC module, and a controller. The high voltage DC-DC modules are electrically separated, the first high voltage DC-DC module is connected to a first high voltage interface of a high voltage system and to a first low voltage interface of a low voltage system, and being of a first DC-DC module type, and the second high voltage DC-DC module is connected to a second high voltage interface of the high voltage system and to a second low voltage interface of the low voltage system, and being of a second different DC-DC module type. The controller is configured to control power supply via one of the high voltage DC-DC modules to the low voltage system in case of failure affecting the other one of the high voltage DC-DC modules.