Integrated Vehicle Power Supply for LDC Failure Backup
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Solution Overview
Problem
Commercial environment-friendly vehicles, such as electric trucks and hydrogen electric buses, face power supply instability due to failures in low voltage DC-DC converters and battery equalizers, leading to potential discharge of auxiliary batteries and failure of 12 V electric loads.
Innovation Solution
An integrated power supply system with two low voltage DC-DC converters and an integrated controller that adjusts output voltages and requests fail-safe conditions through CAN communication, ensuring stable power supply to both 12 V and 24 V electric loads by connecting auxiliary batteries in series and managing current balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate LDC and BEQ systems are used for 12V and 24V power supply, then power supply stability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the LDC and BEQ functions into a single integrated power supply system. The integrated controller manages both 12V and 24V output channels, consolidating what were previously separate systems into one unified device, thereby reducing component count and system complexity while maintaining power supply stability
Solution Approach 2:
The integrated power supply performs multiple functions: it operates as an LDC for 24V output, as a BEQ for 12V output, and can dynamically switch between modes. The single device handles both voltage levels and provides battery equalization functionality, making it a universal power management solution
2Device complexity
If integrated power supply is used to reduce complexity, then device complexity is reduced, but reliability deteriorates due to potential single point of failure
Solution Approach 1:
The integrated power supply is divided into independent output channels (12V channel and 24V channel) with separate control logic for each. The controller can independently manage each channel and detect failures in one channel without affecting the other, allowing segmented fault isolation and continued operation of unaffected channels
Solution Approach 2:
The integrated controller continuously monitors the status of both 12V and 24V output channels and auxiliary batteries. When a failure is detected in one channel, the controller receives feedback and automatically adjusts operation to maintain power supply stability, such as preventing excessive discharge of auxiliary batteries or switching to alternative power paths
3Use of energy by moving object
If auxiliary batteries are connected in series for 24V supply, then power efficiency is improved, but risk of excessive discharge increases when LDC fails
Solution Approach 1:
The integrated controller proactively monitors the state of charge of auxiliary batteries before failure occurs. When LDC failure is detected, the controller has already prepared by monitoring battery status and can immediately take protective action to prevent excessive discharge, rather than waiting for the discharge problem to develop
Solution Approach 2:
The power supply system dynamically adjusts its operation based on real-time conditions. The controller can change the operating mode of the integrated power supply, adjust current limits, and modify power distribution to auxiliary batteries depending on their charge state and load requirements, providing adaptive protection against excessive discharge
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
The solution reduces design costs, size, and weight while ensuring stable power supply to both voltage levels and improving efficiency during fail-safe situations, preventing excessive discharge and maintaining vehicle operation.
Implementation Method 1
a first low voltage DC-DC converter (LDC) that converts supply power to a first output voltage... a second LDC that converts the supply power to a second output voltage
Data Source
AI summary
An integrated power supply includes a first low voltage DC-DC converter (LDC) that converts supply power to a first output voltage and provides the first output voltage to a first auxiliary battery and a first electric load connected to each other in parallel; a second LDC that converts the supply power to a second output voltage and provides the first output voltage to a second auxiliary battery and a second electric load connected to each other in parallel; and an integrated controller that controls the first LDC and the second LDC to change output voltages of the first LDC and the second LDC. The first auxiliary battery and the second auxiliary battery are connected in series, and when the first LDC fails, the second LDC outputs a second increase output voltage that is higher than the second output voltage under control of the integrated controller.