Dual-Voltage Load Management Controller for DC-DC Converter Saturation
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Solution Overview
Problem
Existing electrical load management systems are inadequate for dual-voltage vehicle power supply systems, as they behave non-linearly due to DC-DC converter saturation, and fail to effectively manage electrical loads across high and low voltage networks, leading to inefficiencies and increased costs.
Innovation Solution
An electrical load management system that includes a controller with a processor and memory to determine and control electrical loads on both high and low voltage networks, using predefined load values and priority ratings to manage activation and deactivation of vehicle electrical systems, and adjust power settings to prevent DC-DC converter saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a DC-DC converter is used to connect high and low voltage networks, then power conversion between voltages is enabled, but the system behaves non-linearly due to converter saturation
Solution Approach 1:
The patent applies dynamics by making the control strategy adaptive rather than static. The controller dynamically adjusts its operation based on real-time monitoring of DC-DC converter saturation status. When saturation is detected, the system switches to an alternative control mode that prioritizes loads on the network with sufficient power headroom, thereby maintaining reliable linear behavior while preserving power conversion capability.
2Device complexity
If existing load management systems are used for single voltage networks, then load management is simplified, but they are not suitable for dual-voltage electrical systems
Solution Approach 1:
The patent implements universality by designing a load management controller that can handle both single-voltage and dual-voltage configurations. The controller monitors power availability on both high and low voltage networks, determines DC-DC converter saturation status, and dynamically selects appropriate control strategies. This multi-functional approach enables the same system to adapt to different voltage configurations without requiring separate management systems.
3Power
If the high voltage network powers all electrical systems, then power availability increases, but the low voltage network is still required for certain operations
Solution Approach 1:
The patent applies segmentation by dividing the vehicle's electrical systems into high voltage and low voltage categories, with the controller intelligently determining which network should power each system based on real-time conditions. The system segments the control strategy into different modes: when the high voltage network has sufficient headroom, it powers systems directly; when saturation occurs, the controller switches low voltage systems to be powered from the high voltage network through the DC-DC converter, thereby optimizing power utilization across both networks.
Data Source
AI summary
An electrical load management system for a vehicle power supply system having a high voltage network and a low voltage network coupled to each other by a DC-DC converter includes a controller for controlling one or more high voltage vehicle electrical systems connected to the high voltage network and one or more low voltage vehicle electrical systems connected to the low voltage network. The controller has at least one processor that receives command signals for the high and low voltage vehicle electrical systems, and a memory device having instructions stored therein. The at least one processor is configured to determine a first electrical load on the high voltage network and a second electrical load on the low voltage network in dependence on the command signals and to control operation of the high and low voltage vehicle electrical systems in dependence on the determined first and second electrical loads.