Fault-Tolerant DC-DC Converter With Seamless Topology Reconfiguration
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Solution Overview
Problem
Conventional voltage converters, especially those used in electric vehicles, are prone to failures due to overcurrent, overvoltage, short-circuits, or open-circuits, leading to system shutdown and safety concerns, particularly in autonomous driving applications where availability is critical.
Innovation Solution
A fault-tolerant DC-DC converter with seamless reconfiguration topology is introduced, utilizing a mirrored configuration of the secondary portion of the converter without full redundancy. This design employs a natural path reconfiguration and a simple referral system, such as a buck-boost converter, to maintain output voltage and current capacity even if a current control device fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full redundancy with two separate transformers and stages is implemented, then system availability and safety are improved, but device size and cost increase significantly
Solution Approach 1:
The patent merges the primary and secondary converter stages into a single integrated topology where the same power stage serves both functions. The converter uses a single transformer and power stage that can operate in either primary or secondary mode, eliminating the need for separate redundant transformers and stages while maintaining fault tolerance capability.
Solution Approach 2:
The converter design implements multi-functionality by creating a universal power stage that can perform both primary conversion and secondary conversion functions. The same circuitry and components serve multiple purposes: the single transformer and power stage can operate in primary mode during normal conditions and automatically switch to secondary mode upon fault detection, providing full redundancy functionality without duplicating hardware.
2Reliability
If full redundancy with two separate transformers and stages is implemented, then system availability and safety are improved, but system cost increases
Solution Approach 1:
The patent merges the primary and secondary converter stages into a single integrated topology where the same power stage serves both functions. The converter uses a single transformer and power stage that can operate in either primary or secondary mode, eliminating the need for separate redundant transformers and stages while maintaining fault tolerance capability.
Solution Approach 2:
The converter design implements multi-functionality by creating a universal power stage that can perform both primary conversion and secondary conversion functions. The same circuitry and components serve multiple purposes: the single transformer and power stage can operate in primary mode during normal conditions and automatically switch to secondary mode upon fault detection, providing full redundancy functionality without duplicating hardware.
3Device complexity
If conventional non-redundant topology is used, then device complexity and cost are reduced, but system availability deteriorates upon component failure
Solution Approach 1:
The converter employs dynamic reconfiguration capability where the system can automatically switch its operational mode in response to fault conditions. The control circuitry continuously monitors the health of power switching devices and dynamically reconfigures the circuit topology by activating alternative current paths, enabling the system to adapt its structure based on real-time operational status without requiring manual intervention or system shutdown.
Solution Approach 2:
The converter utilizes parameter changes in the circuit configuration to achieve fault tolerance. By changing the switching states of the power devices and reconfiguring the circuit topology through controlled parameter adjustments, the system can transition from a single-path configuration to an alternative path configuration, maintaining functionality despite component failures while keeping the physical hardware unchanged.
Data Source
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AI summary
A fault tolerant DC-DC converter including a transformer and a pair of mirrored power converters. The transformer has a primary inductance driven by a power supply and has a secondary inductance with an intermediate tap. A main power converter includes first and second current control devices, a first inductance, and a first capacitance coupled to the secondary inductance for developing a main voltage output. A mirrored power converter includes third and fourth current control devices, a second inductance, and a second capacitance also coupled to the secondary inductance for developing a mirrored voltage output. Output circuitry couples to the main and mirrored power converters to share power to a load, such as a battery. The output circuitry may be configured as a buck boost converter that is responsive to a failure of any of the current control devices to maintain the primary output voltage level at a regulated level.