Reconfigurable Vehicle DC Electrical System for AC Power Generation

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Solution Overview

Problem

Existing vehicle electrical systems face challenges in meeting high AC power demands, particularly when parked, due to the need for duplicate components and limited packaging space, which increases manufacturing costs and complexity.

Innovation Solution

A reconfigurable DC electrical system that includes a switch module to interconnect battery bus segments, allowing a single alternator to operate at either 12V or 24V, enabling efficient AC power generation for AC inverters without the need for additional alternators, by switching between nominal and dual voltage states based on the vehicle's state.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a separate 24V battery and alternator are added to supply power to the AC inverter, then the AC power output capacity is improved, but the device complexity and manufacturing costs increase

Engineering Contradiction:

ImproveAC power output capacityVSAvoidelectrical system complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent combines the 12V and 24V electrical systems into a single integrated architecture. The same alternator and battery serve dual purposes: providing 12V power to DC loads during normal operation, and providing 24V power to the AC inverter when needed. This merging eliminates the need for separate duplicate components while maintaining full AC power capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alternator and battery are designed to perform multiple functions: they serve as the primary power source for 12V DC loads during driving, and as the power source for 24V AC inverter operation when parked. This multi-functionality eliminates the need for dedicated separate components for AC power generation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If two or more alternators connected in parallel are used, then the available power is improved, but the packaging space requirement increases

Engineering Contradiction:

Improveavailable electrical powerVSAvoidengine compartment space

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

Instead of installing multiple separate alternators to increase power capacity, the patent merges the electrical systems so that a single alternator provides power for both 12V DC loads and 24V AC inverter operations. This consolidation maintains full power availability while eliminating the need for additional alternator units and their associated mounting space.

Inventive Principle:

Principle #5Merging (Combining)

3Power

If a separate 24V battery and alternator are connected to supply power to the AC inverter, then the AC power generation capability is improved, but the manufacturing cost increases

Engineering Contradiction:

ImproveAC power generation capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The patent merges the 12V and 24V electrical systems into a single integrated architecture where the same alternator and battery serve dual purposes. This eliminates the need to manufacture, source, and install separate duplicate components, thereby reducing manufacturing costs while maintaining full AC power generation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alternator and battery are designed with multi-functionality to serve both 12V DC loads and 24V AC inverter operations. This universal design eliminates the need for dedicated separate components, reducing the total bill of materials and manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for efficient operation of high-power AC inverters up to 4 kW without additional alternators, reducing manufacturing costs and optimizing space usage, while maintaining power to both AC and DC loads during parked and idling states.

Implementation Method 1

A first alternator driven by the powertrain system provides a regulated voltage to the second bus segment

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

A first battery provides a nominal DC voltage between respective positive and negative terminals

Methodology Applied

Scientific EffectElectrochemical energy conversion: Battery (electricity)

Implementation Method 3

An AC inverter has a parked/idling mode that generates AC power at an outlet when a high DC voltage greater than the nominal DC voltage is supplied to an input of the AC inverter

Methodology Applied

Scientific EffectPower conversion:

Data Source

PatentUS11458914B2Method of onboard AC power generation for vehicles with combustion engine

Publication Date: 2022.10.04 FORD GLOBAL TECH LLC

AI summary

An AC inverter in a vehicle operates using a 24 V input when a vehicle powertrain is in a parked/idling state. A first 12 V battery is connected with a first bus segment. A second 12 V battery is connected with a second bus segment. A switch module selectably interconnects the first and second bus segments. In a nominal 12 V state, the batteries are connected in parallel from the bus segments to ground. In a dual voltage state, the batteries are connected in series so the first bus segment is at 12 V and the second bus segment is at 24 V. A first alternator driven by the powertrain provides a regulated voltage to the second bus segment, wherein the regulated voltage corresponds to 12 V when the switch module is in the nominal state and corresponds to 24 V when the switch module is in the dual voltage state.