Vehicle Power Module Linking Dual-Voltage Redundant Load Paths
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Solution Overview
Problem
Existing vehicle electrical systems lack sufficient redundancy in energy supply to safety-relevant consumers, which can lead to failures in critical systems during power line or component faults, compromising vehicle safety and integrity.
Innovation Solution
A vehicle electrical system with two electrical subsystems of different voltage layers, each connected to multiple energy sources and component electrical systems, where safety-relevant consumers are connected via two separate power supply lines and energy sources, ensuring double redundancy through both power and energy source redundancy, utilizing a power module with DC-DC converters and switches for efficient voltage conversion and system connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single power supply line is used to connect safety-relevant consumers to energy sources, then the device complexity is reduced, but the reliability of energy supply deteriorates due to lack of redundancy
Solution Approach 1:
The electrical system is segmented into two independent component electrical systems (first and second component electrical systems) within the same electrical subsystem. Each component electrical system has its own power supply line, creating redundancy for safety-relevant consumers. This segmentation allows the system to maintain reliability through multiple independent paths while keeping each individual path relatively simple.
Solution Approach 2:
The system implements beforehand cushioning by providing redundant power supply lines and component electrical systems before any failure occurs. When a fault is detected in one power supply line or component electrical system, the system can immediately switch to the redundant path, cushioning against the impact of the failure and maintaining continuous operation of safety-relevant consumers.
2Reliability
If safety-relevant consumers are connected to both electrical subsystems via multiple power supply lines, then the reliability is improved through double redundancy, but the device complexity increases
Solution Approach 1:
The power module serves multiple functions: it manages power distribution within the electrical subsystem, enables inter-subsystem power exchange through DC-DC converters, and provides redundant power paths for safety-relevant consumers. By making the power module universal and multi-functional, the system achieves high reliability without proportionally increasing overall device complexity, as a single component performs multiple critical roles.
Solution Approach 2:
The power module acts as an intermediary between the first and second electrical subsystems, managing the complexity of inter-subsystem connections. It contains DC-DC converters that facilitate controlled power exchange and switching mechanisms that manage redundant power paths. This intermediary structure isolates the complexity of redundancy management within the power module, preventing it from propagating throughout the entire electrical system.
3Loss of energy
If higher voltage is used in the second electrical subsystem, then the power delivery efficiency is improved with reduced current consumption, but the safety requirements for isolation increase
Solution Approach 1:
DC-DC converters are introduced as intermediary devices between the low-voltage first electrical subsystem and the high-voltage second electrical subsystem. These converters provide galvanic isolation and controlled energy transfer, enabling the system to exploit the efficiency benefits of high voltage (reduced current consumption) while maintaining safety through isolated power stages. The converters act as mediators that prevent direct electrical connection between different voltage domains.
Solution Approach 2:
The system changes the voltage parameter across different electrical subsystems, with the first electrical subsystem operating at a lower voltage layer and the second electrical subsystem operating at a higher voltage layer. This parameter change optimizes power delivery efficiency in the high-voltage subsystem by reducing current consumption. The patent explicitly addresses the resulting safety concerns by implementing appropriate isolation measures and protective mechanisms between the different voltage layers.
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 configuration provides enhanced safety and reliability by ensuring continuous energy supply to safety-relevant consumers even in case of faults, optimizing power delivery with higher voltage operation and reduced current consumption, while maintaining system compactness and integration.
Implementation Method 1
a power module (28), which connects the two electrical subsystems (6, 8) to one another and in which each of the two power supply lines (V1, V2) is connectable to the two energy sources (10, 12), with the result that power can be supplied to the consumer (16) via the two power supply lines (V1, V2) in each case from both energy sources (10, 12)
Data Source
AI summary
A vehicle electrical system for a vehicle includes first and second subsystems, each connected to at least one energy source. The first and second subsystems have different voltage levels. At least one safety-relevant load is connected to one of the subsystems, this subsystem having two partial systems, and the load being connected to both partial systems so that the load is connected to the energy source of the subsystem via two separate supply lines. A power module, which connects the two subsystems to each other and is designed such that each of the two supply lines can be connected to both energy sources so that the load can be supplied from both energy sources via both supply lines. There is also described a corresponding power module.