Modular DC/DC Converter Mounting Base for Scalable Power Systems
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Solution Overview
Problem
Existing electric vehicle power systems are heavy, space-intensive, and unsustainable due to the use of fixed-size DC/DC converters and lead-acid batteries, which fail to adapt to varying power needs efficiently.
Innovation Solution
A modular mounting base for DC/DC converter units with standardized mechanical and electrical connectors, a cooling channel, and switching members that allows for flexible configuration and redundancy, enabling scalable power distribution and reduced weight and space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed-size DC/DC converters and lead-acid batteries are used, then power supply reliability is ensured, but weight and space requirements increase significantly
Solution Approach 1:
The power supply system is divided into multiple modular DC/DC converter units that can be independently configured and combined. Each unit is a self-contained module with standardized interfaces, allowing the system to be segmented into discrete functional blocks that can be selectively assembled based on power requirements, thereby reducing overall weight while maintaining reliability through redundancy.
Solution Approach 2:
The mounting base is designed with universal mechanical and electrical connectors that can interface with different types and numbers of DC/DC converter units. This multi-functional interface allows the same base structure to support various configuration scenarios, enabling the system to adapt to different power requirements without requiring separate heavy infrastructure for each configuration.
2Device complexity
If fixed-size DC/DC converters are used, then system simplicity is maintained, but adaptability to varying power needs is reduced
Solution Approach 1:
The system is segmented into standardized modular units with uniform connectors and interfaces. This segmentation maintains simplicity at the module level while enabling complex configurations through combinatorial assembly, allowing the system to adapt to varying power needs by simply adding or removing modules rather than redesigning the entire system.
Solution Approach 2:
The mounting base incorporates switching members that enable dynamic reconfiguration of electrical connections between converter units and secondary devices. This dynamic switching capability allows the system to adapt its power distribution topology in real-time based on operational requirements, providing versatility while maintaining a relatively simple static structure.
3Stability of the object's composition
If lead-acid batteries are used for secondary devices, then power supply stability is achieved, but environmental sustainability and space requirements are compromised
Solution Approach 1:
The modular DC/DC converter units are designed as replaceable modules that can be individually serviced or replaced without affecting the entire system. This approach allows for more sustainable maintenance practices where individual units can be refurbished or replaced independently, reducing the environmental impact compared to replacing entire heavy battery systems, while maintaining power supply stability through continuous operation of remaining units.
4Power
If multiple DC/DC converter units are connected to mounting base, then power output is increased, but system complexity increases
Solution Approach 1:
Multiple DC/DC converter units are merged into a single integrated power supply system through the mounting base that provides unified mechanical support, common cooling infrastructure, and centralized electrical distribution. This merging approach allows the system to achieve high power output by combining multiple units while managing complexity through integration at the base level rather than requiring complex interconnections between individual units.
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
The solution provides a cost-effective, scalable, and sustainable power system that adapts to varying power requirements, reduces weight and space, and enhances safety by allowing independent operation of DC/DC converter units and efficient power distribution.
Implementation Method 1
a cooling channel extending in heat conducting contact along the mounting areas
Data Source
AI summary
A mounting base can comprise: a group of mounting areas, each mounting area of the group of mounting areas comprising: a respective mechanical connector member of a group of respective mechanical connector members for attaching to a complementary mechanical connector member on each direct-current to direct-current (DC/DC) converter unit of the group of DC/DC converter units, and a respective electrical connector of a group of respective electrical connectors for attaching to a complementary electrical connector on each DC/DC converter unit of the group of DC/DC converter units, a group of electrical conductors attached to the group of respective electrical connectors in each mounting area, and attached to a main connector on the mounting base for connecting to a high-voltage (HV) connector of a main HV supply, and a cooling channel extending in heat conducting contact with the group of mounting areas.