Modular DC-DC Converter Reconfiguration for Vehicle Voltage Matching
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Solution Overview
Problem
Existing DC-DC converters for vehicle-to-vehicle charging systems are inefficient and require robust hardware to handle wide voltage ranges, leading to larger, heavier, and less efficient charging solutions.
Innovation Solution
A modular DC-DC converter system using galvanically-isolated, modular first and second converters with a DC voltage bus and electronic control, allowing for real-time or preconfigured switching to match the voltage levels of donor and recipient vehicles, utilizing lower-voltage modular converters in series or parallel arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single robust DC-DC converter is used to handle wide voltage ranges, then voltage adaptability is improved, but device complexity and weight increase
Solution Approach 1:
The patent divides a single robust DC-DC converter into multiple modular converter units, each designed to handle a specific narrow voltage range. These modular units can be connected in series or parallel configurations to adapt to different voltage requirements, thereby achieving wide voltage range handling without requiring a single complex converter design.
Solution Approach 2:
The patent implements dynamic reconfiguration capability where the modular converter units can be dynamically switched between series and parallel connections based on real-time voltage requirements. This dynamic adaptability allows the system to optimize its configuration for different operating conditions without physical reconfiguration.
2Reliability
If robust hardware is used to handle wide voltage ranges, then reliability is improved, but weight and size increase
Solution Approach 1:
By segmenting the converter into multiple modular units, each unit can be optimized for a specific voltage range, allowing the use of lighter components rated for narrower voltage ranges rather than requiring heavy-duty components capable of handling the entire voltage spectrum simultaneously.
Solution Approach 2:
The modular converter units are designed with universal interfaces and control mechanisms that allow them to function in different configurations (series or parallel), enabling a single modular unit to serve multiple voltage range requirements without requiring separate dedicated hardware for each voltage level.
3Power
If a single high-power converter is used, then power transfer capability is improved, but charging efficiency decreases due to thermal stress
Solution Approach 1:
The patent segments the high-power conversion task across multiple modular converter units, allowing the power load to be distributed among several units operating at lower individual power levels. This distribution reduces thermal stress on each unit, improving overall charging efficiency while maintaining the required total power transfer capability.
Solution Approach 2:
The patent combines multiple modular converter units to achieve high power transfer capability, where the units work in parallel or series-parallel configurations. This merging approach allows the system to achieve high total power output while each individual unit operates at optimal efficiency levels, reducing cumulative thermal losses.
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
Improves charging efficiency and reduces thermal stress by using modular converters that are scalable and efficient, providing enhanced mobility and flexibility in charging operations.
Implementation Method 1
a galvanically-isolated and modular first DC-DC converter having a predetermined voltage rating, a galvanically-isolated and modular second DC-DC converter having the predetermined voltage rating
Implementation Method 2
The controller is configured to convert an input voltage of the DC voltage bus into an output voltage via switching control signals to the first DC-DC converter and the second DC-DC converter
Data Source
AI summary
A converter system, e.g., for vehicle-to-vehicle charging, includes galvanically-isolated modular first and second converters having the same maximum voltage rating, a direct current (DC) voltage bus interconnecting the converters, and an electronic controller. An input voltage to the DC bus is converted into an output voltage via switching control signals to the modular converters. The system's voltage rating may equal the maximum of the input and/or output voltage, or it may equal the maximum input voltage and be about 50-percent of the maximum output voltage. The maximum input and output voltages may be equal. When the voltage rating is about 50-percent of the maximum input voltage, capacitors may be connected in parallel with the modular converters on an input side thereof. Switching circuits may be connected to the bus to control the conversion of the input voltage via switching control signals.