Dual Power Supply System for Electric Vehicles

Solution Overview

Problem

Existing dual power supply systems for electric vehicles require significant installation space, increase weight, and elevate production costs due to separate 48V and 12V battery systems and DC/DC converters, which are insufficient for dynamic power management and security functions.

Innovation Solution

A dual power supply system with interconnected battery cell stacks and a DC/DC converter that provides redundant power and active balancing between two battery cell stacks, integrated into a common housing, allowing for efficient voltage conversion and management between 48V and 12V board nets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate 48V and 12V battery systems with DC/DC converters are used, then reliable power supply to different board nets is achieved, but installation space, weight, and production costs increase significantly

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines separate 48V and 12V battery systems into a single integrated dual-power battery system. The 48V battery module and 12V battery module share a common housing, control unit, and thermal management system, eliminating the need for separate DC/DC converters and reducing overall system weight while maintaining reliable power supply to both board nets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control unit in the integrated system performs multiple functions: it manages charging and discharging for both 48V and 12V battery modules, monitors system state, and controls thermal management. This multi-functional approach replaces the need for separate control systems and DC/DC converters, reducing weight and installation space while ensuring reliable power distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate 48V and 12V battery systems with DC/DC converters are used, then reliable power supply to different board nets is achieved, but installation space requirements increase

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines separate 48V and 12V battery systems into a single integrated dual-power battery system. The 48V battery module and 12V battery module share a common housing, control unit, and thermal management system, eliminating the need for separate DC/DC converters and reducing overall system weight while maintaining reliable power supply to both board nets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The 12V battery module is positioned within the same housing as the 48V battery module, creating a nested or space-sharing arrangement. This allows both battery systems to coexist in a compact configuration, significantly reducing the total installation space required compared to separate systems with dedicated housings and converters.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If separate 48V and 12V battery systems with DC/DC converters are used, then power conversion between voltages is achieved, but production costs increase

Engineering Contradiction:

Improvevoltage conversion capabilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The control unit in the integrated system performs multiple functions: it manages charging and discharging for both 48V and 12V battery modules, monitors system state, and controls thermal management. This multi-functional approach replaces the need for separate control systems and DC/DC converters, reducing weight and installation space while ensuring reliable power distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent extracts and eliminates the separate DC/DC converter component from the system architecture. Instead, the control unit directly manages power conversion and distribution between the 48V and 12V battery modules, simplifying the system structure and reducing production costs while maintaining voltage adaptability.

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If multiple separate components (48V battery system, 12V battery system, DC/DC converter) are used, then flexible power management is achieved, but device complexity increases

Engineering Contradiction:

Improvepower management flexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines separate 48V and 12V battery systems into a single integrated dual-power battery system. The 48V battery module and 12V battery module share a common housing, control unit, and thermal management system, eliminating the need for separate DC/DC converters and reducing overall system weight while maintaining reliable power supply to both board nets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control unit in the integrated system performs multiple functions: it manages charging and discharging for both 48V and 12V battery modules, monitors system state, and controls thermal management. This multi-functional approach replaces the need for separate control systems and DC/DC converters, reducing weight and installation space while ensuring reliable power distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system reduces production costs, weight, and installation space while ensuring secure and efficient power supply to different board nets in electric vehicles by utilizing the DC/DC converter for both redundant power and active balancing, ensuring continuous operation even in case of cell failures.

Implementation Method 1

a DC/DC converter with a first converter node, a second converter node and a third converter node. The DC/DC converter is configured for converting a first voltage (input voltage) between the second converter node and one of the first converter node and the third converter node to a second voltage (output voltage) between the second converter node and the other one of the first converter node and the third converter node

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11407311B2Dual power supply system

Publication Date: 2022.08.09 SAMSUNG SDI CO LTD

AI summary

A dual power supply system with first to third system terminals is disclosed. The dual power supply system includes a first battery cell stack interconnected between first and second stack nodes and providing a first operation voltage and a second battery cell stack interconnected between the second stack node and a third stack node and providing a second operation voltage. The dual power supply system further includes a DC/DC converter with first to third converter nodes and configured to convert a voltage of the first or second battery cell stack. Each of the system terminals is connected to the respective stack node or converter node in parallel. The DC/DC converter can provide redundant power supply and active balancing. The application further relates to a vehicle including the above dual power supply system.