Multi-Voltage DC-DC Converter for Eco-Friendly Vehicles
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Solution Overview
Problem
The increasing electric field load in eco-friendly vehicles necessitates a solution for providing multi-voltage outputs to various electric subassemblies and electronic subassemblies, as existing low voltage DC-DC converters face challenges in fuel efficiency, size, and manufacturing costs due to increased capacity and complexity.
Innovation Solution
A low voltage DC-DC converter apparatus and method that includes an AC voltage converting unit, transformer, rectifying unit, LC filter, and converter to provide both 48V and 12V outputs, with a control unit to calculate power consumption and select operation modes for efficient power distribution from a high voltage battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple low voltage DC-DC converters are used to provide different voltages for various electric subassemblies, then the power supply requirements for different electric subassemblies are met, but the device complexity, size, and manufacturing costs increase
Solution Approach 1:
The patent applies multi-functionality by enabling a single low voltage DC-DC converter to provide multiple voltage outputs (12V and 48V) simultaneously. The converter includes a primary winding connected to the high voltage battery, a secondary winding providing 12V output, and a tertiary winding providing 48V output. This allows one device to replace multiple converters, reducing system complexity while maintaining the capability to power different electric subassemblies with different voltage requirements
Solution Approach 2:
The patent combines multiple converter functions into a single integrated device. The low voltage DC-DC converter integrates the functions of what would traditionally require separate 12V and 48V converters by incorporating multiple windings on a shared magnetic core. The converter simultaneously generates both voltage levels from a single high voltage input, merging multiple power conversion paths into one unified system
2Adaptability or versatility
If the capacity of low voltage DC-DC converter is increased to meet growing electric field load, then the power supply capability is improved, but the fuel efficiency deteriorates
Solution Approach 1:
The patent implements dynamic operation by enabling the converter to adapt its output configuration based on real-time power demands. The control unit monitors the power consumption of electric subassemblies and dynamically adjusts whether to output 12V, 48V, or both voltages simultaneously. This dynamic adaptability allows the system to maintain high power supply capability while minimizing energy conversion losses by activating only the necessary output paths
3Adaptability or versatility
If multiple converters are mounted in the vehicle, then the required voltages for electric subassemblies are provided, but the vehicle size and manufacturing costs increase
Solution Approach 1:
The patent applies multi-functionality by enabling a single low voltage DC-DC converter to provide multiple voltage outputs (12V and 48V) simultaneously. The converter includes a primary winding connected to the high voltage battery, a secondary winding providing 12V output, and a tertiary winding providing 48V output. This allows one device to replace multiple converters, reducing system complexity while maintaining the capability to power different electric subassemblies with different voltage requirements
Solution Approach 2:
The patent combines multiple converter functions into a single integrated device. The low voltage DC-DC converter integrates the functions of what would traditionally require separate 12V and 48V converters by incorporating multiple windings on a shared magnetic core. The converter simultaneously generates both voltage levels from a single high voltage input, merging multiple power conversion paths into one unified system
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 reduces the need for multiple converters, saving space, cost, and maintenance time by providing a single unit that efficiently manages power distribution to different electric subassemblies, enhancing fuel efficiency and reducing the overall size and manufacturing costs of eco-friendly vehicles.
Implementation Method 1
converts the supplied DC power of the high voltage into AC power of a high voltage having a desired pulse width by a full bridge type of pulse width modulation (PWM)
Implementation Method 2
The AC power of the high voltage input from the AC voltage converting unit 111 is transferred from a primary side coil to a secondary side coil, in which the primary side coil and the secondary side coil are mounted in the transformer 112 and are insulated from each other. Further, the AC power of the high voltage input from the AC voltage converting unit 111 is reduced to the AC power of the 12V low voltage depending on a turn ratio of the transformer 112.
Implementation Method 3
The rectifying unit 113 again converts 12V AC power input from the transformer 112 into 12V DC power by an operation of a plurality of mounted rectifying diodes.
Implementation Method 4
the LC filter unit 114 removes a ripple by an operation of the mounted LC filter to convert the 12V DC power into 12V DC power in a smooth state, not a pulse type
Data Source
AI summary
An apparatus for providing a multi-voltage output of a low voltage DC-DC converter of an eco-friendly vehicle may include a transformer converting AC power of the high voltage into AC power of a first voltage, a rectifying unit generating the AC power of the first voltage as DC power of a first voltage, a first voltage output unit supplying the first voltage to a first electric field load of the eco-friendly vehicle from the DC power of the first voltage, a converter converting the DC power of the first voltage into DC power of a second voltage having a voltage value different from the first voltage, and a second voltage output unit supplying the second voltage from the DC power of the second voltage to a second electric field load.