Integrated Voltage Converter Relay for Vehicle Power Distribution
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Solution Overview
Problem
Current vehicle power distribution systems face challenges with limited flexibility and increased complexity due to the need for dual voltage systems, which often require additional batteries and complex wiring, especially when transitioning from 12V or 24V to higher voltage levels like 48V, and struggle with accommodating a wide range of voltage requirements for various vehicle components.
Innovation Solution
A vehicle power distribution system utilizing a monolithic solid state relay with integrated voltage conversion circuitry that can step-down nominal voltages (such as 48V) to rated voltages (like 12V) using a transistor, diode, inductor, and capacitor configuration, along with a PWM controller, allowing for selective energization of loads and reducing the need for additional batteries and complex wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dual voltage distribution system with high power bi-directional converter is used to connect 12V/24V to 48V systems, then voltage compatibility for various accessories and components is improved, but device complexity increases due to additional converters and wiring harnesses
Solution Approach 1:
The patent combines the voltage conversion function and relay switching function into a single integrated device. The solid state relay includes integrated circuitry that converts 48V to 12V/24V while simultaneously controlling the relay output, eliminating the need for separate DC/DC converters and reducing wiring complexity.
Solution Approach 2:
The solid state relay performs multiple functions: it acts as a voltage converter (48V to 12V/24V), a relay switch, and a protection device. This multi-functional design allows a single component to replace what would traditionally require multiple separate components, reducing overall system complexity.
2Adaptability or versatility
If a second auxiliary battery is added to support legacy 12V components in a 48V system, then voltage compatibility is improved, but device complexity and cost increase due to additional batteries and monitoring systems
Solution Approach 1:
The patent eliminates the need for a second auxiliary battery by integrating voltage conversion capability directly into the solid state relay. The relay converts 48V power to the required 12V/24V levels on-demand, removing the battery, charging system, and monitoring equipment that would otherwise be required.
3Adaptability or versatility
If additional copper wiring is used in complex wiring harnesses to supply each voltage level to loads throughout the vehicle, then voltage compatibility is improved, but weight and device complexity increase
Solution Approach 1:
The patent consolidates power distribution by integrating the voltage conversion function into the relay located at the load. This eliminates the need for separate high-power DC/DC converters and their associated heavy copper wiring, as the conversion happens directly at the point of use through the solid state relay circuitry.
4Device complexity
If traditional relays without integrated voltage conversion are used, then device complexity is reduced, but adaptability to different voltage requirements of various components deteriorates
Solution Approach 1:
The patent merges the voltage conversion circuitry directly into the relay device, allowing a single component to handle both relay switching and voltage conversion functions. This integration maintains the simplicity of traditional relays while adding the adaptability needed for multi-voltage systems.
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 enables a flexible power distribution system that can accommodate a wide range of voltage requirements without the need for a second auxiliary battery or high-power DC/DC converters, reducing system complexity and copper usage, while maintaining high efficiency across varying output power ranges.
Implementation Method 1
a controller coupled to the transistor and configured to generate a pulse width modulated (PWM) switching signal having a duty cycle based on the nominal voltage and the rated voltage
Data Source
AI summary
A vehicle power distribution system includes a battery having a nominal voltage, a vehicle electrical load having a supply voltage different than the nominal voltage, and a monolithic solid state relay including integrated circuitry to convert the nominal voltage to the rated voltage and an output configured to selectively energize the vehicle electrical load with the rated voltage in response to a control signal from a vehicle controller applied to an input of the relay. The relay may include a PWM controller to provide a switching signal to a transistor connected to an output filter to step down the nominal voltage of the battery to the rated voltage of the vehicle electrical load. Relay output voltage and current monitoring circuitry may be connected to the PWM controller to provide over current and over voltage protection.