Integrated DC Converter Assembly for Multi-Voltage Vehicle Power
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Solution Overview
Problem
Existing electrical high-voltage on-board power supply systems for vehicles are inflexible and costly, as they require separate components and structures for different voltage levels and functions, which complicates the management of various low-voltage power supplies and increases costs.
Innovation Solution
A modular direct current converter system with shared components, including a DC/DC converter, EMC filter, and intermediate circuit, housed in a single unit, allowing for conversion of high-voltage to multiple low-voltage levels and enabling activation/deactivation of subsystems for different functions, thereby simplifying structure and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate components and structures are used for different voltage levels, then voltage conversion functionality is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple direct current converter modules with different input and output voltages into a single integrated component housed in a shared housing. This merging of previously separate components reduces structural complexity while maintaining the ability to convert high voltage to multiple different low voltage levels, directly resolving the contradiction between functionality and complexity.
Solution Approach 2:
The integrated direct current converter is designed with multiple converter modules that can handle different voltage conversions (e.g., 400V to 12V, 400V to 48V, 800V to 12V, 800V to 48V) within a single component. This multi-functional design allows one component to replace multiple separate converters, reducing overall system complexity while maintaining versatility across different voltage requirements.
2Adaptability or versatility
If separate components are used for different voltage levels, then voltage conversion is achieved, but manufacturing cost increases
Solution Approach 1:
By merging multiple converter modules into a single integrated component with shared housing and common structural elements, the patent reduces the total number of parts that need to be manufactured, assembled, and tested. This consolidation lowers manufacturing costs while maintaining the capability to perform multiple voltage conversions.
Solution Approach 2:
The universal design of the integrated converter allows a single component to serve multiple voltage conversion functions, eliminating the need to manufacture and stock multiple separate converter units. This multi-functionality reduces manufacturing complexity and cost while maintaining adaptability to different voltage requirements.
3Reliability
If all subsystems remain active, then power supply availability is maintained, but energy consumption increases during low load conditions
Solution Approach 1:
The patent implements dynamic control of the converter modules, allowing individual modules to be selectively activated or deactivated based on real-time power supply requirements. This dynamic adjustment enables the system to maintain reliability by keeping necessary modules active while reducing energy consumption by switching off unnecessary modules during low load conditions.
Solution Approach 2:
The system can temporarily deactivate (discard) certain converter modules when their functions are not currently needed, and reactivate them when required. This selective deactivation reduces energy consumption during low load conditions while maintaining the capability to restore full functionality when needed, effectively managing the trade-off between reliability and energy use.
Data Source
AI summary
A direct current converter includes a plurality of direct current converter modules having electrical input voltages and output voltages that differ from each other. The plurality of direct current converter modules are electrically connectable to one another to form a plurality of subsystems such that a high-voltage electrical voltage is convertible into different low-voltage electrical voltages. The plurality of direct current converter modules are configured as a shared integrated assembly. At least one of the plurality of subsystems is always active.