Power Supply System with Redundant Switching Elements
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Solution Overview
Problem
Conventional power supply systems in hybrid and electric vehicles face challenges in performing voltage conversion when a switching element experiences an ON fault, leading to safety issues and the need to stop voltage stepping up/down.
Innovation Solution
A power supply system with a configuration that includes two batteries, multiple switching elements, and system main relays, where the controlling portion performs ON-OFF controls to maintain voltage conversion even during an ON fault by switching between different operational modes and adjusting the connection between batteries and switching elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional voltage transducer with switching elements is used, then voltage conversion can be performed under normal conditions, but voltage conversion cannot be performed when a switching element has an ON fault
Solution Approach 1:
The voltage transducer is divided into multiple independent switching elements (S1, S2, S3, S4) that can operate independently. When one switching element has an ON fault, the system can segment the operation to use only the healthy switching elements, maintaining voltage conversion capability while isolating the faulty component.
Solution Approach 2:
The system dynamically adjusts its operation mode based on the health status of switching elements. The control unit detects ON faults and switches between different operational modes (normal mode, degraded mode with single battery, or failsafe mode), allowing the system to adapt to varying fault conditions and maintain reliability.
2Productivity
If voltage transducer continues operation after switching element ON fault, then productivity is maintained, but safety risks increase due to potential voltage exceeding system limits
Solution Approach 1:
The control unit continuously monitors the operational status of switching elements and provides feedback to adjust the operation mode. When an ON fault is detected, the feedback mechanism triggers a mode switch to degraded or failsafe operation, preventing voltage from exceeding system withstanding limits while maintaining continuous voltage conversion capability.
Solution Approach 2:
The system dynamically changes its operational configuration based on real-time fault detection. By switching between normal, degraded, and failsafe modes, the system maintains productivity through continuous operation while adapting to fault conditions that would otherwise create safety hazards.
3Object-affected harmful factors
If system stops voltage conversion at ON fault to ensure safety, then harmful effects are prevented, but productivity is reduced
Solution Approach 1:
Instead of completely stopping voltage conversion, the system dynamically adapts by switching to degraded or failsafe modes that maintain limited voltage conversion capability. This dynamic response prevents total system shutdown while ensuring safety through controlled operation with reduced functionality.
Solution Approach 2:
The system converts the harmful effect of a switching element ON fault into a beneficial operational mode change. By detecting the fault and switching to degraded or failsafe modes, the system uses the fault condition as a trigger for adaptive operation, maintaining safety while preserving partial productivity rather than complete shutdown.
Data Source
AI summary
A power supply system comprises a first battery, a second battery, an output electric circuit, a first switching element, a second switching element, and a third switching element. The output electric circuit includes a first electric circuit and a second electric circuit. The second electric circuit has a potential lower than a potential of the first electric circuit. The first, second and third switching elements are provided in series with each other from the first electric circuit toward the second electric circuit. The first battery is provided in parallel with the second switching element. The second battery is provided in parallel with a series connection between the second switching element and the third switching element.