Modular Power Supply Assembly With Isolated Reversible DC/DC Balancing
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Solution Overview
Problem
Existing power supply systems for rotating electrical machines in vehicles face challenges in intelligently controlling energy discharge across modules to ensure equitable load balancing and safety, particularly for low-voltage consumers and autonomous driving systems requiring isolated voltage sources.
Innovation Solution
A power supply assembly comprising a chain of modules with isolated and reversible DC/DC converters, dual power supply buses, and a control unit to manage energy transfer between modules, ensuring balanced energy distribution and redundancy, while providing isolated voltage sources for different consumers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional non-isolated DC/DC converters are used, then device complexity is reduced, but safety and isolation requirements for autonomous driving systems cannot be met
Solution Approach 1:
The system divides the power supply into multiple independent modules, each with its own isolated DC/DC converter. This segmentation allows each module to operate independently with proper isolation, meeting safety requirements while maintaining manageable complexity through modular design.
Solution Approach 2:
The isolated DC/DC converter is designed to serve multiple functions: providing galvanic isolation for safety, enabling bidirectional energy flow for load balancing, and supporting both charging and discharging operations. This multi-functionality justifies the increased complexity by eliminating the need for separate components.
2Reliability
If energy storage units discharge independently without coordination, then device complexity is reduced, but load balancing across modules cannot be achieved
Solution Approach 1:
The control system continuously monitors the state of charge of each energy storage unit and adjusts the switching of isolated DC/DC converters accordingly. This feedback mechanism enables automatic load balancing by redirecting energy flow from modules with high charge to modules with low charge, achieving equitable discharge without manual intervention.
Solution Approach 2:
The system dynamically adjusts the operation of isolated DC/DC converters based on real-time conditions. The converters can switch between charging and discharging modes, and the control algorithm adapts the energy flow distribution to maintain balanced load across all modules, transforming a static system into a dynamically responsive one.
3Adaptability or versatility
If single power supply bus is used, then device complexity is reduced, but ability to provide isolated voltage sources for different consumers is limited
Solution Approach 1:
The power supply architecture is segmented into multiple independent power supply buses, each serving specific consumers with isolation requirements. This segmentation allows different consumers to receive power from isolated sources, enhancing versatility while keeping each bus segment manageable in complexity.
Solution Approach 2:
The isolated DC/DC converters act as intermediaries between the energy storage units and the power supply buses. They provide galvanic isolation and voltage conversion, enabling the system to deliver isolated voltage sources to different consumers while managing the complexity of the multi-bus architecture through standardized conversion interfaces.
4Productivity
If modules operate independently without energy transfer capability, then device complexity is reduced, but energy efficiency and service life extension cannot be improved
Solution Approach 1:
The system merges multiple independent module operations into a coordinated network through isolated DC/DC converters. This allows energy to be transferred between modules, optimizing overall system efficiency by directing energy flow to where it is most needed and extending service life through balanced usage, while maintaining modular independence.
Solution Approach 2:
The system enables energy recovery between modules by allowing discharged modules to transfer energy to modules that need charging. This recovers energy that would otherwise be wasted, improving overall efficiency and extending service life, with the isolated DC/DC converters managing the bidirectional energy flow.
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 enhances energy transfer efficiency, extends module service life, ensures safety, and improves autonomy by balancing energy storage across modules, supporting both low-voltage and high-voltage consumers.
Implementation Method 1
An isolated and reversible DC/DC converter is presented in a known manner in the form of a circuit having a primary circuit and a secondary circuit, the primary circuit and the secondary circuit having at least one controllable switch and a winding, the windings of the primary and secondary circuits being coupled so as to form a transformer
Data Source
Figure 1~2b
Figure 2c~3
AI summary
Assembly (103) for powering a rotating electrical propulsion machine (102) of a vehicle comprising: - at least one chain (30) of modules (10) comprising a first terminal (37a) and a second terminal (37b) each module (10) comprising: - a primary terminal (11a) and a secondary terminal (11b), the primary terminal (11a) being connected to the secondary terminal (11b) of another module (10) and/or the secondary terminal (11b) is connected to the primary terminal (11a) of another module (10), - an electrical energy storage unit (12), - an H-shaped switching bridge (13), comprising controllable switches (14a, 14b, 14c, 14d), each midpoint of the bridge being connected to one of the terminals (11a, 11b) of the module (10), the electrical energy storage unit (12) being arranged in a branch in parallel with the switching arms, and - at least one module (10) comprising a DC/DC converter (15), comprising controllable switches,connected on the one hand to the terminals of the electrical energy storage unit (12) and on the other hand to a tertiary terminal (16a) and to a quaternary terminal (16b) of the module (10), - a first and a second power supply bus (110, 112), intended to be connected to a respective electrical consumer and/or electrical energy storage unit, each chain comprising at least one module (10) having its tertiary (16a) and quaternary (16b) terminals connected to the first power supply bus (110) and at least one module (10) having its tertiary (16a) and quaternary (16b) terminals connected to the second power supply bus (112), the modules (10) of each chain (30) being in particular distributed between modules (10) having their tertiary (16a) and quaternary (16b) terminals connected to the first power bus (110) and modules (10) having their tertiary (16a) and quaternary (16b) terminals connected to the second power bus (112),Characterized in that at least one DC/DC converter (15) of a module (10) of each chain (30) is an isolated and reversible converter.