Dual IPS ECU Power Control for Inrush Current Continuity
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Solution Overview
Problem
Existing power control systems for in-vehicle ECUs often mistakenly cut off power due to inrush currents, leading to interruptions in power supply, which existing intelligent power switches (IPS) fail to address effectively.
Innovation Solution
A power control apparatus and method that utilizes a lookup table with recorded inrush current values for each ECU, employing a main and backup IPS to ensure continuous power supply by activating the backup IPS when the main IPS detects an inrush current exceeding a threshold, with support from a vehicle management server for data management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single intelligent power switch (IPS) is used to supply power to ECUs, then the device complexity is reduced, but the power supply reliability deteriorates due to false overcurrent detection from inrush currents
Solution Approach 1:
The single IPS is segmented into a main IPS and a backup IPS. The main IPS handles normal power supply operations, while the backup IPS is specifically designated to handle inrush current events. This segmentation allows each IPS to have specialized functionality, resolving the contradiction by maintaining simplicity in control logic while improving reliability through redundant hardware.
Solution Approach 2:
The backup IPS is pre-configured and ready before inrush current events occur. The system proactively prepares the backup IPS by monitoring inrush current characteristics and pre-charging the backup IPS before the main IPS needs to be interrupted. This preliminary action ensures seamless power supply transition without interruption, resolving the reliability issue while maintaining manageable system complexity.
2Object-affected harmful factors
If the main IPS is interrupted due to inrush current detection, then the overcurrent protection function is improved, but the power supply to ECUs is interrupted
Solution Approach 1:
The backup IPS acts as an intermediary power supply during inrush current events. When the main IPS detects inrush current and needs to be interrupted for protection, the backup IPS seamlessly takes over as the intermediary power source, maintaining continuous power supply to ECUs. This intermediary mechanism resolves the contradiction by enabling overcurrent protection while preventing power supply interruption.
Solution Approach 2:
The system provides beforehand cushioning by preparing the backup IPS in advance of inrush current events. The backup IPS is pre-charged and positioned to immediately take over when the main IPS is interrupted. This prior cushioning ensures that the transition from main IPS to backup IPS is seamless, resolving the contradiction between overcurrent protection and power supply continuity.
3Reliability
If a backup IPS is introduced to ensure continuous power supply, then the power supply reliability is improved, but the device complexity increases
Solution Approach 1:
The control logic for the main IPS and backup IPS is merged into a unified control system. Rather than implementing separate independent control circuits, the patent integrates the control of both IPSs into a single coordinated system that manages switching between them. This merging approach reduces the overall control complexity while maintaining the reliability benefits of having a backup IPS.
Solution Approach 2:
The backup IPS is designed with multi-functionality, serving both as a standby power source during normal operations and as an active power source during inrush current events. The unified control system provides universal management for both IPSs, allowing the same control logic to handle both normal and abnormal operating conditions. This universality reduces complexity by avoiding the need for separate specialized control circuits.
Data Source
AI summary
A power control apparatus includes a main switch that supplies or cuts off power to in-vehicle electronic control units (ECUs). The power control apparatus also includes a backup switch that supplies or cuts off the power to the in-vehicle ECUs. The power control apparatus additionally includes a storage that stores a lookup table in which inrush current values respectively corresponding to the ECUs are recorded. The power control apparatus further includes a controller that collects ECU information on the in-vehicle ECUs, turns on the main switch when a sum of the inrush current values respectively corresponding to the ECUs exceeds a threshold current value, and turns on the backup switch at a preset time.