Integrated Ultracapacitor DC-DC Converter for LV Backup Power
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Solution Overview
Problem
In vehicle power networks, the loss of high-voltage supply or DC-DC converter can lead to immediate loss of low-voltage power, necessitating a reliable energy storage solution to maintain functionality during failures.
Innovation Solution
A system utilizing a set of ultracapacitors arranged in series or parallel, integrated with a DC-DC converter and transformer, enabling bi-directional power flow to supply energy to the low-voltage network in case of high-voltage failure, and synchronous rectification for efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If batteries are used for energy storage in vehicle power networks, then longer run-time and higher energy density are achieved, but lifespan is reduced and reliability during high-power pulse demands is insufficient
Solution Approach 1:
The power network is segmented into two distinct energy storage systems: batteries for long-duration energy storage and ultracapacitors for short-duration high-power pulses. This segmentation allows each component to operate in its optimal performance range, with batteries providing extended run-time and ultracapacitors providing high-reliability pulse power, thereby resolving the contradiction between run-time and lifespan.
Solution Approach 2:
The patent combines batteries and ultracapacitors into a hybrid energy storage system that leverages the complementary strengths of both technologies. The ultracapacitor module handles high-power transient demands while the battery provides sustained energy storage, creating a unified system that achieves both long run-time and high reliability/lifespan simultaneously.
2Power
If ultracapacitors are used for short-duration high-power applications, then power density and lifespan are improved, but energy storage capacity by weight and volume is reduced
Solution Approach 1:
The energy storage function is segmented between two technologies: ultracapacitors handle short-duration high-power demands where power density is critical, while batteries provide the bulk energy storage capacity. This segmentation allows the system to achieve high power density for pulses without requiring the ultracapacitor to provide all energy storage, thereby overcoming the limitation of reduced energy storage capacity by weight and volume.
Solution Approach 2:
The hybrid system merges ultracapacitor and battery modules to combine their capabilities. The ultracapacitor provides high power density for transient loads while the battery supplies the necessary energy storage capacity, creating a unified system that achieves both high power and sufficient energy storage capacity simultaneously.
3Reliability
If separate energy storage systems are used for high-voltage and low-voltage networks, then functional independence is achieved, but device complexity increases
Solution Approach 1:
The patent merges the high-voltage and low-voltage energy storage systems into a unified hybrid architecture where ultracapacitor modules serve both voltage levels through bidirectional DC-DC converters. This integrated design maintains functional independence between high-voltage and low-voltage networks while reducing overall system complexity by eliminating redundant components and enabling shared control strategies.
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
Ensures continued operation of low-voltage networks by providing temporary power during high-voltage failures, enhancing reliability and extending the lifespan of vehicle electrical systems.
Implementation Method 1
a transformer having a primary winding electrically connected to the high-voltage side and a secondary winding electrically connected to the low-voltage side
Implementation Method 2
a set of ultracapacitors arranged in series or parallel, integrated with a DC-DC converter and transformer
Data Source
Figure 1A
Figure 1B
Figure 2
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.