Regenerative Braking Resistor Circuit With Semiconductor Switching
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Solution Overview
Problem
Existing drive systems for powered systems, such as vehicles, experience wear and tear on components like contactor switches and braking resistors due to discrete braking processes during regenerative and rheostatic braking modes, leading to increased maintenance and replacement costs.
Innovation Solution
A drive system that incorporates semiconductor switches, contactors, and braking resistors, where the semiconductor switches can pulse or open/close to control current flow through the braking resistors, allowing for continuous and controlled braking with reduced arcing and wear, and utilizing inductors and diodes to manage energy flow during braking modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactor switches are used to control current conduction during braking, then braking control is achieved, but arcing and wear on components occur
Solution Approach 1:
The patent replaces mechanical contactor switches with semiconductor switches (IGBTs) to control current conduction during braking. This substitution eliminates the mechanical contact and arcing issues associated with traditional contactors, while maintaining the ability to control current flow through the braking resistor. The semiconductor switches provide contactless switching, thereby eliminating wear and arcing problems.
Solution Approach 2:
The patent introduces semiconductor switches as an intermediary component between the motor and the braking resistor. These switches act as a mediator that controls current flow without direct mechanical contact, replacing the traditional contactor switch arrangement. The semiconductor switches enable precise control of regenerative and rheostatic braking while eliminating the harmful arcing effects.
2Ease of operation
If discrete braking steps are used with contactor switches, then braking control is achieved, but maintenance and replacement costs increase
Solution Approach 1:
The patent replaces the mechanical contactor switch system with a semiconductor-based switching system. This substitution maintains the discrete braking control functionality while eliminating the wear and tear that leads to maintenance and replacement needs. The semiconductor switches have no moving parts or contact surfaces that wear, significantly reducing maintenance requirements.
Solution Approach 2:
The patent enables dynamic control of braking through semiconductor switches that can rapidly change their conduction state. This dynamic switching capability allows for precise control of braking force while eliminating the mechanical wear associated with traditional contactor switches. The system can adjust braking intensity smoothly without the limitations of mechanical switch durability.
3Reliability
If multiple contactors and braking resistors are used, then braking functionality is improved, but device complexity increases
Solution Approach 1:
The patent designs the semiconductor switch circuit to perform multiple functions: it controls both regenerative braking (returning energy to the power source) and rheostatic braking (dissipating energy as heat) using the same switching components. The semiconductor switches can be configured to route current through different paths, eliminating the need for separate contactor switches for each braking mode and reducing overall system complexity.
Solution Approach 2:
The patent combines the control functions of multiple contactor switches into a single semiconductor switching system. The semiconductor switches integrate the functions of switching, current control, and braking mode selection into one unified component set, reducing the number of separate components needed and simplifying the overall system architecture while maintaining full braking functionality.
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 provides a system with reduced wear and tear on components, enabling smoother and more controlled braking with fewer moving parts, thereby lowering manufacturing complexity and costs.
Implementation Method 1
the regenerated electric current from the motor can be conducted to the braking resistor and dissipated as heat
Data Source
AI summary
A system comprising resistive circuit legs coupled with and disposed between (a) a converter that converts electric current for a motor of a powered system and (b) a source of electric current for powering the motor, each of the circuit legs including a braking resistor coupled with the converter, a contactor coupled with the braking resistor such that the braking resistor is between the converter and the contactor, and a semiconductor switch coupled with the contactor such that the contactor is between the semiconductor switch and the braking resistor, where, during a regenerative braking mode of operation of the powered system, the regenerated energy from the motor is conducted to the braking resistor and dissipated as heat.