Integrated Automotive Power Supply Module for Vehicle Architecture Simplification
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Solution Overview
Problem
Conventional motor vehicle stop-start systems face challenges in simplifying topology, reducing weight and connector count, and maintaining voltage support during engine restarts, which can affect critical loads.
Innovation Solution
An integrated power supply module that includes a start-stop DC/DC converter, a DC/AC converter, and an auxiliary DC/DC converter in a common housing, with features like EMI filtering, surge protection, and overcurrent protection, allowing for direct bypass of the DC/DC converter to critical loads and AC/USB outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate converters (stop-start DC/DC converter, auxiliary DC/DC converter, inverter) are used in conventional topologies, then voltage support and power conversion functions are provided, but device complexity and connector count increase
Solution Approach 1:
The patent combines the stop-start DC/DC converter, auxiliary DC/DC converter, and inverter into a single integrated power conversion module. This merging of previously separate converters into one unified device reduces the number of connectors and harnesses while maintaining all necessary voltage support and power conversion functions, directly resolving the contradiction between reliability and device complexity.
2Power
If multiple separate converters are used in conventional topologies, then power conversion functions are provided, but weight increases
Solution Approach 1:
By integrating multiple power conversion functions into a single module, the patent eliminates redundant structural components, housings, and mounting hardware that would exist if separate converters were used. This consolidation maintains full power conversion capability while significantly reducing the overall weight of the power supply system.
3Adaptability or versatility
If multiple separate converters are used in conventional topologies, then power conversion functions are provided, but connector count and harness length increase
Solution Approach 1:
The integrated power conversion module provides multiple output ports (DC output port, AC output port, USB output port) that can serve different functions and external devices. This multi-functional design allows a single device to replace multiple separate converters, maintaining adaptability and versatility while dramatically reducing the number of connectors and harnesses required in the vehicle electrical system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies vehicle architecture, reduces weight and connector count, provides stable voltage support, and achieves higher efficiency, potentially eliminating the need for fans and improving EMC performance, while supporting up to 800W of power with reduced harmonic distortion.
Implementation Method 1
a start-stop DC/DC converter (26), a DC/AC converter (42), and an auxiliary DC/DC converter (44)
Implementation Method 2
a DC/AC converter (42), and an auxiliary DC/DC converter (44)
Data Source
AI summary
A power supply and an automotive topology that includes the power supply, the power supply having an integrated module, which includes in a common, shared module housing, a start-stop DC/DC converter, a DC/AC converter, and an auxiliary DC/DC converter, which bypasses stop/start during non-stop/start operation. A DC input port connected to the start-stop DC/DC converter, DC/AC converter, and the auxiliary DC/DC converter. A DC output port connected to the start-stop DC/DC converter to supply DC to critical loads of a motor vehicle, even during vehicle OFF mode. An AC output port connected to the DC/AC converter to supply AC to an external component.