Vehicle Voltage Converter Matrix for 48V-to-12V Power Distribution
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Solution Overview
Problem
Conventional vehicle electrical systems require two main distributions for 48V and 12V voltage levels, leading to complex and inefficient power management, with high electrical losses and weight due to large cross-sections and redundant components.
Innovation Solution
A multiphase converter system that provides a single 48V main distribution, using e-fuse converters with parallel DC/DC converters to supply 12V participants, offering adjustable current-carrying capacity and voltage levels, and acting as both a voltage converter and electronic fuse for overcurrent protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If a single 48V main distribution is used instead of separate 48V and 12V distributions, then weight and material usage are reduced, but the current-carrying capacity requirement increases
Solution Approach 1:
The distribution network is segmented into a high-voltage 48V main distribution backbone and multiple low-voltage 12V sub-distributions via decentralized converters. This allows the 48V main distribution to carry lower currents over longer distances with smaller cross-sections, while local 12V converters handle high-current demands near consumers, reducing overall weight and material usage.
Solution Approach 2:
Different parts of the electrical system receive different voltage levels according to their specific needs. The 48V main distribution provides power over long distances with low current, while 12V decentralized converters provide high current locally near consumers. This local adaptation of voltage levels optimizes both weight and current-carrying capacity requirements.
2Adaptability or versatility
If decentralized 48V/12V converters are used instead of a central converter, then system flexibility and modularity are improved, but device complexity increases
Solution Approach 1:
The decentralized converters are designed as universal modules that can be deployed throughout the vehicle electrical system. Each converter unit performs multiple functions: voltage conversion from 48V to 12V, electronic fusing for overcurrent protection, and local power distribution. This multi-functionality reduces the need for separate components and simplifies the overall system architecture despite the distributed nature.
Solution Approach 2:
The decentralized converters act as intermediary devices between the 48V main distribution and 12V consumers. They mediate the voltage and current characteristics to match consumer requirements, providing a standardized interface that simplifies system integration while enabling flexible configuration and easy replacement of individual units.
3Quantity of substance
If e-fuse converters are used that combine voltage conversion and overcurrent protection, then component count is reduced, but control system complexity increases
Solution Approach 1:
The e-fuse converter merges the voltage conversion function and overcurrent protection function into a single integrated device. The converter simultaneously performs 48V to 12V conversion while providing electronic fusing through current monitoring and controlled disconnection. This integration reduces the total number of components while the control logic manages both functions through unified control circuits.
4Power
If multiple phases are connected in parallel to increase current capacity, then current-carrying capacity is improved, but configuration complexity increases
Solution Approach 1:
The phase configuration is made dynamic and reconfigurable rather than fixed. Switching elements allow phases to be connected in parallel or series depending on the current requirements of the consumer. This dynamic reconfiguration capability enables the system to adapt to different power demands while maintaining a relatively simple basic structure that can be flexibly arranged.
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 solution reduces electrical losses, weight, and material usage while enabling higher power dynamics and flexible voltage distribution, eliminating the need for separate 12V battery and distribution networks, and providing redundant power supply for functional safety.
Implementation Method 1
The phase voltages can be configured via software, for example, by pulse width modulation (PWM) with duty cycle on the longitudinal transistor of the multiphase converter
Implementation Method 2
a plurality of small DC/DC downward converters connected in parallel
Data Source
AI summary
A device for providing one or more functional voltages in a vehicle electrical system for the supply of electrical components. The device includes: a device input, on which a battery voltage can be applied, and a plurality of device outputs, to which the electrical components can be connected; a plurality of voltage converters with respective inputs, which are connected to the device input, and respective outputs. Each voltage converter is configured to provide an output voltage at its output based on a voltage applied to the respective input and an adjustable duty cycle. The device includes a control unit that is configured to regulate the duty cycle of the respective voltage converter, in which the outputs of the voltage converter are connected to the device outputs according to a connection matrix to provide a current-carrying capacity of the device outputs adapted to the respective connected component.