Dual DC-DC Modules for Fault-Tolerant Low-Voltage Supply
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Solution Overview
Problem
In electric vehicles, the DC-DC converter is more stressed and complex due to its need to maintain power supply to low voltage system loads under various scenarios, and its failure can lead to risks such as deep discharge of low voltage batteries, especially when the vehicle is parked for extended periods.
Innovation Solution
A converter system with two independent DC-DC modules and control units, where each module is connected to both high and low voltage interfaces, allowing for power transfer between systems and enabling the system to maintain power availability even if one module fails, using digital signal processors for fault detection and rerouting power through independent interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single DC-DC converter is used to transfer power from high voltage to low voltage system, then the device complexity is reduced, but the reliability of power supply deteriorates because the converter is more stressed and vulnerable to failures
Solution Approach 1:
The patent divides the single DC-DC converter into two separate DC-DC converters (first DC-DC converter and second DC-DC converter). Each converter is connected to independent high voltage interfaces, allowing the system to segment the power conversion function across multiple independent units, thereby reducing stress on each individual converter while improving overall reliability.
Solution Approach 2:
The patent implements a backup mechanism where the second DC-DC converter is prepared in advance to take over power supply duties if the first DC-DC converter fails. The control unit monitors the operational status of both converters and can switch to the backup converter before complete system failure occurs, cushioning against potential failures.
2Use of energy by moving object
If the DC-DC converter is turned off during key-off state to save energy, then energy consumption is reduced, but the reliability of low voltage system power supply deteriorates when parked for extended periods
Solution Approach 1:
The patent prepares a backup power supply path through the second DC-DC converter before the low voltage battery suffers deep discharge. If the first DC-DC converter is off during key-off state, the control unit can activate the second DC-DC converter to maintain minimum power supply to critical loads, preventing complete system shutdown even during extended parking periods.
3Device complexity
If a single DC-DC converter is used, then the device complexity is lower, but the adaptability to handle different failure scenarios deteriorates
Solution Approach 1:
By segmenting the power conversion function into two independent DC-DC converters with independent high voltage interfaces, the system gains adaptability to handle various failure scenarios. Each converter can operate independently or in combination, allowing the system to adapt to different operational requirements and failure modes.
Solution Approach 2:
The patent implements dynamic switching capability where the control unit can dynamically change the operational status of each DC-DC converter based on system requirements and failure conditions. This dynamic reconfiguration allows the system to adapt to different scenarios, such as turning off one converter during normal operation while keeping the other active for backup.
Data Source
AI summary
A converter system for transferring power, a vehicle including such a converter system and a method for transferring power in such a converter system. The converter system includes a first DC-DC module, a second DC-DC module and a first control unit. The first DC-DC module is connected to a first high voltage interface of a high voltage system and to a first low voltage interface of a low voltage system. The second DC-DC module is connected to a second high voltage interface of the high voltage system and to a second low voltage interface of the low voltage system. The first high voltage interface and the second interface are independent of each other. The first control unit is connected to the first DC-DC module and configured to supply power via the second DC-DC module in case of a failure in the first DC-DC module.