Vehicle PCB Layout for Dual 12V/48V Power and Control
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Solution Overview
Problem
The existing vehicle electrical systems, particularly those using 12V or 48V, face challenges in meeting the increasing power demands due to evolving comfort systems, with 12V systems being inadequate and 48V systems being costly, necessitating a dual 12V/48V system conversion that is time-consuming and expensive.
Innovation Solution
A printed circuit board design with separate power and control areas, allowing operation in both 12V and 48V systems, featuring coupling components and conductor tracks for electrical coupling, enabling seamless transition between voltage levels without additional assembly steps, and using galvanically isolated or opto-couplers for signal exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a pure 48V vehicle electrical system is used, then the power requirements for basic systems and comfort systems are met, but the production cost and end price of the motor vehicle increase significantly
Solution Approach 1:
The circuit board is designed with universal compatibility for both 12V and 48V electrical systems through integrated power conversion capability. The board can function as a 12V control unit, a 48V control unit, or a dual-voltage converter, eliminating the need for separate dedicated boards for each voltage level and reducing overall system cost.
Solution Approach 2:
The circuit board incorporates voltage conversion capability that allows dynamic parameter change between 12V and 48V operation. By including power conversion circuitry (such as DC-DC converters) on the same board, the system can adapt its voltage parameter to match different operational requirements without requiring complete system redesign.
2Ease of manufacture
If a pure 12V vehicle electrical system is used, then the production cost is reduced, but the power requirements for basic systems and comfort systems cannot be met
Solution Approach 1:
The circuit board is designed with universal compatibility for both 12V and 48V electrical systems through integrated power conversion capability. The board can function as a 12V control unit, a 48V control unit, or a dual-voltage converter, eliminating the need for separate dedicated boards for each voltage level and reducing overall system cost.
Solution Approach 2:
The circuit board is pre-equipped with power conversion circuitry and dual-voltage capability during manufacturing. This preliminary action ensures that when the vehicle electrical system needs to be upgraded from 12V to 48V, the control units are already capable of handling both voltages, eliminating the need for complete system replacement and reducing upgrade costs.
3Adaptability or versatility
If a dual 12V/48V vehicle electrical system is implemented, then both power requirements and future-proofing are achieved, but the conversion from 12V to dual 12V/48V system is time-consuming and expensive
Solution Approach 1:
The circuit board is designed with universal compatibility for both 12V and 48V electrical systems through integrated power conversion capability. The board can function as a 12V control unit, a 48V control unit, or a dual-voltage converter, eliminating the need for separate dedicated boards for each voltage level and reducing overall system cost.
Solution Approach 2:
The circuit board is pre-equipped with power conversion circuitry and dual-voltage capability during manufacturing. This preliminary action ensures that when the vehicle electrical system needs to be upgraded from 12V to 48V, the control units are already capable of handling both voltages, eliminating the need for complete system replacement and reducing upgrade costs.
4Reliability
If separate additional circuit boards are used for high-voltage circuits, then the power circuit and control circuit are separated, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent combines both the power circuit and control circuit onto a single circuit board. The power conversion circuitry (such as DC-DC converters) and control electronics are integrated on the same board, eliminating the need for separate additional circuit boards and simplifying the assembly process while maintaining proper circuit separation through PCB design techniques.
Data Source
Figure 1
AI summary
The invention relates to an equipped circuit board (1) for an electrical system (16) of a motor vehicle (17), having a circuit board body (2), on which a power circuit (5) and a control circuit (6) are formed, wherein the power circuit (5) is connected to the control circuit (6). According to the invention, it is essential that the circuit board according to the invention both enables the power circuit and the control circuit to operate at the same voltage level, wherein the power circuit is coupled to the control circuit via coupling conductor tracks, and also enables the control circuit and the power circuit to operate at different voltage levels, wherein the power circuit is coupled to the control circuit via at least one coupling component.