Bidirectional Charger Topology for EV Torque Vectoring Motors
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Solution Overview
Problem
Existing electrified vehicles require multiple components to drive torque vectoring control motors, increasing complexity and reducing efficiency.
Innovation Solution
The vehicle employs a bidirectional charger with a DC/DC converter to drive the torque vectoring control motor, reducing the number and area of elements needed by separating the three-phase DC/DC converter into a single-phase DC/DC converter and a single-phase inverter during vehicle operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate inverter is added to drive the torque vectoring control motor, then the motor can be driven independently, but the number of components and system complexity increase
Solution Approach 1:
The patent merges the inverter function into the bidirectional charger by adding a third leg to the DC/DC converter. This allows the charger to directly drive the torque vectoring control motor without requiring a separate inverter component, thus reducing system complexity while maintaining independent torque vectoring control capability.
Solution Approach 2:
The bidirectional charger is designed to perform multiple functions: it can charge the battery from the external power source, discharge the battery to external loads, and simultaneously drive the torque vectoring control motor. This multi-functionality eliminates the need for dedicated separate components for each function.
2Productivity
If a three-phase DC/DC converter is used for battery charging, then charging efficiency is improved, but the converter cannot simultaneously drive single-phase motors like the torque vectoring control motor
Solution Approach 1:
The three-phase DC/DC converter is segmented into three separate legs, with the third leg specifically dedicated to single-phase output capability. This segmentation allows the converter to selectively activate different legs based on the operational mode, enabling both efficient three-phase battery charging and single-phase torque vectoring control.
Solution Approach 2:
The DC/DC converter dynamically switches between different operational configurations by controlling the switching elements in each leg. It can operate as a three-phase converter for battery charging, as a single-phase converter for torque vectoring control, or in combined modes, providing adaptive versatility based on real-time vehicle needs.
3Reliability
If multiple separate systems are used for charging and torque control, then each system can be optimized independently, but the overall vehicle space and component area increase
Solution Approach 1:
The patent combines the charging system and torque control system into a single bidirectional charger unit. By integrating the DC/DC converter with enhanced single-phase and three-phase capabilities, the design eliminates the need for separate inverters and chargers, significantly reducing the overall component area while maintaining the reliability of independently optimized functions.
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 allows for simultaneous torque vectoring control and battery discharging while driving, enhancing efficiency and reducing component requirements.
Implementation Method 1
a transformer connected between the first switching circuit and the second switching circuit
Data Source
AI summary
An electrified vehicle includes a motor including windings, a power factor correction circuit including AC and DC terminals and including legs corresponding to respective AC terminals and connected between the DC terminals, and a DC/DC converter including a first switching circuit including first, second, and third primary legs connected between terminals of a battery, a second switching circuit including at least one secondary leg connected between the DC terminals, and a transformer connected between the first and second switching circuits. In a battery discharging mode, the DC/DC converter switches the first primary leg and the at least one secondary leg, outputting a voltage of the battery to the DC terminals via the transformer. When the motor may be driven, the DC/DC converter switches the second and third primary legs electrically disconnected from the transformer, outputting the voltage of the battery to the motor.