Modular Vehicle Power Conversion with Isolated DC/DC Converters
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Solution Overview
Problem
Current vehicle power conversion systems require large and heavy components designed to withstand high voltages and currents, which is inefficient and may hinder performance and comfort improvements.
Innovation Solution
A power conversion system with a modular design incorporating transformer isolated DC/DC converters and controllers to manage energy transfer between high-voltage and low-voltage systems, using series and parallel connections to reduce component size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large and heavy components are used to withstand high voltages and currents, then system reliability is improved, but device weight increases
Solution Approach 1:
The power conversion system is divided into multiple modular switching converter units (first plurality and second plurality) that can be independently configured. Each module handles a portion of the total power conversion task, allowing the system to achieve high voltage and current handling capability through parallel/series combinations of lighter individual modules rather than requiring a single large heavy component.
Solution Approach 2:
The system uses transformer isolated DC/DC converters that can operate at high frequencies, enabling the use of smaller magnetic components. By changing the operating parameters (frequency, voltage levels) and using isolated conversion topology, the system achieves reliable high-voltage power conversion with reduced component size and weight compared to traditional direct conversion approaches.
2Power
If large and heavy components are used to withstand high voltages and currents, then power conversion capability is improved, but device volume increases
Solution Approach 1:
The power conversion capability is achieved through segmented modular architecture where multiple switching converter units work in parallel/series. This segmentation allows high power conversion capability to be distributed across multiple smaller volume modules rather than requiring a single large volume component.
Solution Approach 2:
The system uses transformer isolation to create an additional dimensional separation between primary and secondary sides, enabling independent optimization of each side's components. This allows high-voltage side to use smaller components operating at higher frequencies while maintaining the required power conversion capability.
3Reliability
If traditional power conversion devices are used, then high-voltage and high-current handling is achieved, but component size and weight increase
Solution Approach 1:
The system employs transformer isolated DC/DC converters operating at high switching frequencies, which fundamentally changes the operating parameters compared to traditional linear converters. This parameter change enables the use of smaller, lighter magnetic components and capacitors while maintaining the same high-voltage handling capability through isolated topology and frequency-based design.
Solution Approach 2:
The system replaces traditional mechanical/electromagnetic power conversion approaches with electronic switching and high-frequency transformer isolation. This substitution of conversion methodology enables high-voltage handling with significantly reduced component weight through electronic control and high-frequency operation rather than low-frequency electromagnetic transformation.
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 system effectively manages high-voltage and low-voltage energy transfer, reducing component size and weight while enhancing vehicle performance and comfort by optimizing power distribution.
Implementation Method 1
Each of the first plurality of switching converters is a transformer isolated DC/DC converter
Data Source
AI summary
A power conversion system includes a rectifier, a first plurality of switching converters, and a first load including a plurality of first load elements. Each of the first plurality of switching converters has a converter first positive port, a converter first negative port, a converter second positive port, and a converter second negative port. The converter first positive port and the converter first negative port of all of the first plurality of switching converters are connected in series to the rectifier. The converter second positive port of at least one of the first plurality of switching converters is connected to a load element positive port of each of the plurality of first load elements. The converter second negative port of at least one of the first plurality of switching converters is connected to a load element negative port of each of the plurality of first load elements.