Bi-Directional HV DC-DC Converter Bypass Detection Without Extra Sensors

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Solution Overview

Problem

Conventional bi-directional high voltage DC-DC converters in fuel cell electric vehicles are prone to bypass events that can damage the power system controller due to unfeasible current control and overcurrent, necessitating a method to detect and avoid such occurrences.

Innovation Solution

A bi-directional high voltage DC-DC converter with a control circuit that detects bypass events by comparing input and output voltages, adjusts current limiting commands, and performs operations to avoid or cope with the bypass without additional sensors, using predefined reference values to manage the converter's operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bi-directional high voltage DC-DC converter operation is used, then power conversion function is provided, but bypass occurs causing controller damage and system failure

Engineering Contradiction:

Improvesystem reliabilityVSAvoidbypass damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The control circuit performs preliminary detection by continuously monitoring the voltage difference between input and output terminals. When the voltage difference falls below a predetermined threshold, the system proactively adjusts the current limiting command before bypass damage can occur, preventing controller failure in advance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control circuit establishes a feedback mechanism that continuously monitors the voltage difference and dynamically adjusts the current limiting command based on real-time conditions. This closed-loop control ensures the converter operates safely by responding to changing voltage conditions and preventing bypass events

Inventive Principle:

Principle #23Feedback

2Difficulty of detecting and measuring

If voltage difference monitoring is implemented to detect bypass, then bypass detection capability is improved, but device complexity increases due to additional sensors

Engineering Contradiction:

Improvebypass detectionVSAvoidsensor quantity

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The control circuit performs multiple functions using existing components: it manages normal power conversion control, monitors voltage difference for bypass detection, and adjusts current limiting commands. By making the control circuit multi-functional, the patent eliminates the need for dedicated bypass detection sensors while maintaining detection capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The control circuit uses its own existing voltage measurement capabilities to monitor the voltage difference between input and output terminals. The system serves itself by utilizing already-present sensing infrastructure for dual purposes: normal operation control and bypass detection, avoiding additional hardware requirements

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12456918B2Bi-directional high voltage DC-DC converter capable of detecting and avoiding bypass and operating method thereof

Publication Date: 2025.10.28 HL MANDO CORP

AI summary

A bi-directional high voltage DC-DC converter capable of detecting and avoiding a bypass and an operating method thereof, by detecting whether a bypass has occurred and performing an operation for avoiding the bypass and/or an operation for coping with the bypass when the occurrence of the bypass is detected, can detect the occurrence of the bypass to avoid system defects, and detect the occurrence of the bypass in an existing system without adding a voltage sensor and a current sensor.