Single-PCB ECU Isolation for 12V and 48V Vehicle Domains
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Solution Overview
Problem
Existing hybrid car electrical systems require multiple electronic control units (ECUs) for different supply voltages, leading to increased footprint, installation space, and costs, with inefficient data transfer and control loops between domains.
Innovation Solution
An electronic control unit (ECU) with a 12V-domain and 48V-domain on a single printed circuit board, galvanically isolated and connected by a galvanically isolated data interface, allowing for half-duplex or full-duplex communication, with the 48V-domain powered by the 12V-domain via a galvanically isolated supply interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate ECUs are used for different supply voltages, then each ECU can be dedicated to a single supply voltage with simple design, but the footprint and installation space increase
Solution Approach 1:
The patent combines multiple ECUs for different supply voltages (12V and 48V) into a single integrated ECU. The control unit includes a first control unit for 12V loads and a second control unit for 48V loads on the same printed circuit board, sharing common components such as oscillators, crystal resonators, and capacitors. This merging reduces the overall footprint and installation space while maintaining dedicated control functionality for each voltage domain.
2Device complexity
If multiple separate ECUs are used for different supply voltages, then each ECU can operate independently with simple power supply, but the costs for design, manufacturing and service increase
Solution Approach 1:
The patent merges multiple ECUs into a single integrated unit that shares common power supply components, oscillators, and other resources. The first and second control units share a common oscillator and crystal resonator, reducing component count and manufacturing complexity. This integration lowers design and manufacturing costs while maintaining independent operational capability through galvanic isolation.
Solution Approach 2:
The integrated ECU implements universal functionality by incorporating multiple control units that can handle different supply voltages (12V and 48V) within a single device. The control unit can selectively activate different domains based on vehicle operating conditions, providing multi-functional capability that reduces the need for multiple separate devices and lowers overall system costs.
3Area of stationary object
If ECUs for different supply voltages are integrated on a single PCB, then footprint and costs are reduced, but galvanic isolation must be maintained between domains
Solution Approach 1:
The patent segments the integrated ECU into galvanically isolated domains (12V domain and 48V domain) on the same printed circuit board. Each domain is electrically isolated using techniques such as optocouplers or transformers for data communication, and isolated power supply circuits. This segmentation maintains electrical safety and noise immunity while allowing physical integration that reduces footprint.
Solution Approach 2:
The patent introduces intermediary components such as optocouplers or isolators that mediate data and power transfer between the 12V and 48V domains. These intermediaries enable communication and power transfer while maintaining galvanic isolation, allowing the domains to operate independently without direct electrical connection, thus managing the complexity of isolation requirements.
4Device complexity
If data transfer between domains uses traditional interfaces, then communication is established, but latency increases and efficiency decreases
Solution Approach 1:
The patent extracts the data transfer interface from traditional slow communication protocols and implements a high-speed dedicated data bus between the first and second control units. This extracted interface operates at higher speeds with lower latency, enabling efficient data exchange between the 12V and 48V domains while maintaining galvanic isolation through the use of isolated communication protocols.
Data Source
AI summary
The disclosure relates to an electronic control unit (ECU) for a vehicle. The ECU includes a 12V-domain controlling an electric load supplied with a first supply voltage and a 48V-domain controlling an electric load supplied with a second supply voltage. Both domains are arranged on a single printed circuit board (PCB) and are galvanically isolated from each other and connected with each other by a galvanically isolated data interface that transfers data between the domains according to a half-duplex or a full-duplex communication protocol. The 48V-domain includes a 48V-microcontroller and a 48V-power supply supplying the 48V-microcontroller, where the 48V-power supply is powered by the first supply voltage from the 12V-domain via a galvanically isolated supply interface.