Parallel DC-DC Converter Control for Stable Power Sharing

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Conventional DC-to-DC converters connected in parallel face challenges in maintaining stable voltage levels across multiple energy storage devices in electric vehicles, leading to undesirable variations in electric power distribution due to differences in voltage sensor tolerances and response times, which can result in inefficient propulsion force generation.

Innovation Solution

A system comprising a first and second DC-to-DC converter connected in parallel, with a controller that measures current through the first converter and adjusts electric power through the second converter based on specific current thresholds to maintain desired voltage levels at the second node, thereby stabilizing voltage and power distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple DC-to-DC converters are connected in parallel to provide electric power, then the power delivery capability is improved, but voltage level stability deteriorates due to sensor tolerances and response time differences

Engineering Contradiction:
Improveelectric power delivery capabilityVSAvoidvoltage level stability
Core Design Contradiction:
PowerVSStability of the object's composition

Solution Approach 1:

The controller continuously measures the current through the first DC-to-DC converter and uses this feedback to dynamically adjust the electric power conveyed through the second DC-to-DC converter. This closed-loop control ensures that voltage variations from one converter are compensated by the other, maintaining stable voltage levels at the second node while utilizing the combined power capacity of both converters.

Inventive Principle:
Principle #23Feedback

2Device complexity

If conventional independent control of each DC-to-DC converter is used, then the device complexity is reduced, but the precision of voltage and power distribution deteriorates

Engineering Contradiction:
Improvecontrol system complexityVSAvoidvoltage and power distribution precision
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The controller merges the control of both DC-to-DC converters into a unified control system. By measuring the current through the first converter and using this information to adjust the second converter's power output, the system achieves coordinated control that improves voltage and power distribution precision without requiring complex independent control circuits for each converter.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12071085B2Controlling DC-to-DC converters connected in parallel
Publication Date: 2024.08.27 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC
  • US12071085B2 patent drawing
  • US12071085B2 patent drawing
  • US12071085B2 patent drawing

AI summary

A system for controlling DC-to-DC converters connected in parallel can include a first DC-to-DC converter, a second DC-to-DC converter, and a controller. The first DC-to-DC converter can be connected between a first node and a second node. The first DC-to-DC converter can be configured to maintain a voltage level at the second node. The second DC-to-DC converter can be connected between the first node and the second node. The controller can be configured to measure a current through the first DC-to-DC converter. The controller can be configured to cause, in response to a measure of the current being in a specific relationship with respect to a threshold current, a change in electric power being conveyed through the second DC-to-DC converter to cause the second DC-to-DC converter to respond to a subsequent change in electric power being conveyed through the second node.