Integrated Ultracapacitor DC-DC Converter for Low-Voltage Backup
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Solution Overview
Problem
In vehicle power systems, the loss of high-voltage supply or DC-DC converter can lead to immediate failure of the low-voltage powernet, necessitating a reliable energy storage solution to maintain functionality during such failures.
Innovation Solution
A system utilizing a set of ultracapacitors connected in series and/or parallel, coupled with a DC-DC converter featuring a magnetic coupling system and switching power electronics, enables bi-directional power flow to ensure energy is stored and temporarily supplied to the low-voltage powernet in case of high-voltage failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultracapacitors are used for energy storage in vehicle power systems, then reliability is improved during high-voltage supply failures, but device complexity increases due to integration of additional components
Solution Approach 1:
The patent combines the ultracapacitor energy storage system with the DC-DC converter into a single integrated unit. The ultracapacitor is electrically connected to the DC-DC converter, allowing the same hardware to perform both power conversion and energy storage functions. This merging reduces overall system complexity despite adding energy storage capability, as the ultracapacitor shares electrical connections and control infrastructure with the existing DC-DC converter.
Solution Approach 2:
The DC-DC converter is designed to serve multiple functions: normal power conversion from high-voltage to low-voltage, and emergency power supply to the low-voltage powernet when high-voltage supply fails. The ultracapacitor integrated with the converter provides both energy storage and backup power functions. This multi-functionality improves reliability without proportionally increasing device complexity, as existing components perform multiple roles.
2Quantity of substance
If ultracapacitors are integrated with DC-DC converter, then energy storage capability is improved for backup power supply, but manufacturing complexity increases
Solution Approach 1:
The ultracapacitor and DC-DC converter are manufactured as an integrated assembly rather than separate components. The electrical connections between the ultracapacitor and converter are established during manufacturing, reducing assembly steps and manufacturing complexity. The integrated design allows for standardized production processes where the energy storage and power conversion components are configured together in a single manufacturing flow.
3Loss of energy
If magnetic coupling system is used to electromagnetically couple switching power electronics, then power transmission efficiency is improved, but device complexity increases
Solution Approach 1:
The magnetic coupling system acts as an intermediary between the switching power electronics and the ultracapacitor/DC-DC converter. The magnetic field serves as the medium for energy transfer, enabling efficient power transmission while isolating the switching electronics from direct electrical connection to the ultracapacitor. This intermediary approach improves power transmission efficiency by reducing electrical losses while the magnetic coupling components are integrated into the existing converter structure, limiting the increase in overall device complexity.
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 configuration ensures continued functionality of the low-voltage powernet by providing temporary energy from ultracapacitors during high-voltage supply failures, enhancing reliability and longevity of vehicle electrical systems.
Implementation Method 1
The magnetic coupling system electromagnetically couples the switching power electronics to the second side of the DC-DC converter
Implementation Method 2
an ultracapacitor may be based on an electrostatic double-layer capacitor or an electrochemical pseudocapacitor
Data Source
AI summary
A system includes a set of ultracapacitors, an input characterized by a first nominal voltage, an output characterized by a second nominal voltage, a direct current to direct current (DC-DC) converter, and switching power electronics electrically connected to the set of ultracapacitors. The DC-DC converter is configured to convert power from the input at the first nominal voltage to power at the output at the second nominal voltage. The DC-DC converter includes a magnetic coupling system that electromagnetically couples a first side of the DC-DC converter to a second side of the DC-DC converter. The magnetic coupling system electromagnetically couples the switching power electronics to the second side of the DC-DC converter.