Integrated Power Converter for Catalyst Heating Without Battery Cycling
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Solution Overview
Problem
High voltage hybrid electric vehicle systems aggressively age batteries due to aggressive cycling from low frequency PWM power switching, which is required for catalyst heating in internal combustion engine powertrains, leading to premature battery degradation and increased system costs.
Innovation Solution
Integrating a secondary output within the existing high voltage hybrid power network's DC/DC converter to support the low voltage power network, allowing for varied power delivery to the catalyst heating element, reducing aggressive battery cycling and potentially improving cost and packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If low frequency PWM power switching is used for catalyst heating, then the catalyst temperature can be controlled, but the battery undergoes aggressive cycling leading to premature degradation
Solution Approach 1:
A DC-DC converter is introduced as an intermediary component between the battery and the catalyst heating element. The converter decouples the direct connection, allowing the battery to operate at stable voltage while the converter handles the PWM switching required for temperature control. This mediator protects the battery from aggressive cycling while enabling effective catalyst heating.
Solution Approach 2:
The power delivery system is segmented into distinct functional components: the battery provides stable power, the DC-DC converter handles voltage conversion and PWM control, and the heating element performs catalyst temperature control. This segmentation isolates the battery from the aggressive switching operations, preserving battery life while maintaining heating functionality.
2Temperature
If a dedicated heating element is added to the exhaust system, then catalyst light-off can be achieved, but system complexity and cost increase
Solution Approach 1:
The DC-DC converter is designed to perform multiple functions: it provides voltage conversion for the low-voltage electrical system and simultaneously serves as the power delivery controller for the catalyst heating element. By making the converter universal, the patent avoids adding a dedicated heating controller, thereby reducing system complexity while achieving catalyst light-off.
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 smooths power delivery to the catalyst heating element, reducing battery degradation and potentially lowering overall system costs by sharing existing components and improving energy efficiency.
Implementation Method 1
a heating element that receives power from the power converter via the second output, and provides heat to a catalyst of an exhaust system
Data Source
AI summary
A vehicle includes a power converter that receives power, and has first and second outputs, a low voltage battery that receives power from the power converter via the first output, and a heating element that receives power from the power converter via the second output, and provides heat to a catalyst of an exhaust system. The vehicle also includes a controller that commands the converter to provide power to the heating element via the second output according to a temperature of the catalyst.