Regenerative Braking Power Modules for Voltage Bypass Continuity
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Solution Overview
Problem
Existing regenerative braking systems for electrically-driven work vehicles face challenges in maintaining operational continuity while preventing device size increase, as they require auxiliary modules and increased withstand voltage for high voltage handling, leading to larger and more complex power conversion devices.
Innovation Solution
A regenerative braking system with a power regeneration device comprising multiple power conversion modules connected in series, where a controller manages the voltage input to prevent exceeding the upper limit by short-circuiting stopped modules and adjusting the voltage limit based on their withstand voltage, allowing for operational continuity without increasing device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auxiliary modules are provided to maintain operational continuity, then reliability is improved, but device complexity increases
Solution Approach 1:
The power conversion device is divided into multiple independent power conversion modules connected in series. Each module can be independently controlled and bypassed, allowing the system to maintain operation when individual modules fail. This segmentation enables operational continuity without requiring complex auxiliary modules, as each module is self-contained and can be isolated independently.
2Reliability
If withstand voltage of module components is increased to handle voltage when modules are stopped, then reliability is improved, but device complexity increases
Solution Approach 1:
The system dynamically adjusts the voltage distribution across power conversion modules based on their operational state. When a module is stopped or bypassed, the controller redistributes the input voltage among the remaining active modules in real-time. This dynamic voltage management allows the system to handle voltage changes without requiring components to be designed for maximum static voltage, reducing complexity while maintaining reliability.
3Reliability
If insulation distance in each module is ensured for increased voltage, then reliability is improved, but device complexity increases
Solution Approach 1:
The insulation requirements are dynamically managed based on the actual voltage distribution across modules. Since the controller adjusts voltage distribution in real-time based on which modules are active, the insulation distance requirements adapt to the current operational state rather than requiring maximum insulation for all possible scenarios. This reduces the complexity of insulation design while ensuring reliability under actual operating conditions.
4Power
If voltage applied to each module is distributed to handle high voltage, then power is improved, but device complexity increases
Solution Approach 1:
The high voltage input is segmented and distributed across multiple power conversion modules connected in series. Each module handles a portion of the total voltage, allowing the system to process high power applications while using modules with lower individual voltage ratings. This segmentation approach enables high power capability without requiring each component to be designed for the full system voltage, thereby reducing overall device complexity.
Data Source
AI summary
A power regeneration device 21 that converts the power of a main engine DC line 16 connected to a main engine power generator 12 through a rectification circuit 14 to supply the converted power to an accessory DC line 34 connected to an accessory power generator 31 through a rectification circuit 32 includes a plurality of power conversion modules 221 to 22N configured such that input sections 221a to 22Na are connected in series. The main engine power generator 12 and a power consumption device 15 are controlled such that a voltage input to the power regeneration device 21 does not exceed a voltage upper limit value Vm and a portion between a positive electrode terminal (+) and a negative electrode terminal (−) of each of the input sections of the power conversion modules to be stopped is short-circuited by a bypass device and the voltage upper limit value Vm is decreased when some of the plurality of power conversion modules 221 to 22N are stopped. With this configuration, operational continuity can be improved while a device size increase is prevented.