Bridge-Arm EV Power Conversion With Integrated Charging Isolation
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Solution Overview
Problem
Current electric vehicle charging technologies have a low integration level, complex structure layout, high costs, and large volume due to separate distribution of charging and motor drive functions, which necessitate integration of these functions to simplify the structure and reduce costs and volume.
Innovation Solution
An energy conversion apparatus integrating a three-phase bridge arm converter, motor winding, and transformer, which enables both motor drive and alternating current charging functions by reusing circuit components, such as bridge arms and switch groups, to increase integration and reduce volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If charging function and motor drive function are separately distributed, then functional independence is maintained, but vehicle integration level is low and structure layout is complex
Solution Approach 1:
The patent merges the charging function and motor drive function into a single integrated energy conversion apparatus. The three-phase bridge arm converter serves dual purposes: it functions as a charging converter when receiving AC charging power and as a motor drive inverter when propelling the vehicle. This merging eliminates the need for separate charging and drive systems, thereby reducing structural complexity while maintaining functional independence through mode switching.
Solution Approach 2:
The three-phase bridge arm converter is designed with multi-functionality, capable of operating in different modes. It can accept AC input for charging the battery pack, convert DC to AC for driving the motor, and even function as a generator during regenerative braking. This universal design allows a single component to replace multiple dedicated components, simplifying the overall vehicle architecture.
2Device complexity
If charging function and motor drive function are integrated, then vehicle integration level increases and structure layout simplifies, but circuit component reuse increases complexity
Solution Approach 1:
The patent employs dynamic switching mechanisms (first switch group and second switch group) that allow circuit components to change their connections and functions based on operational mode. During AC charging, the bridge arms connect to the transformer; during motor drive, they connect to the motor windings. This dynamic reconfiguration enables the same hardware to serve multiple purposes without permanent complex wiring, managing component reuse complexity through controlled switching.
Solution Approach 2:
The switch groups act as intermediaries that manage the complex routing between the bridge arms, transformer, and motor windings. By introducing these switching devices, the patent creates a flexible intermediary layer that simplifies the overall system architecture. The switches enable clean mode transitions and proper signal routing without requiring permanent complex interconnections between all components.
3Reliability
If separate charging and motor systems are used, then functional reliability is maintained, but vehicle volume and costs increase
Solution Approach 1:
The patent combines multiple functional systems (charging converter, motor inverter, battery management) into a single integrated energy conversion apparatus. This merging significantly reduces the volume occupied by electrical systems in the vehicle while maintaining functional reliability through careful design of mode switching and isolation mechanisms. The transformer provides galvanic isolation during charging, and the switch groups ensure proper disconnection between charging and drive modes, preserving safety and reliability.
4Reliability
If separate charging and motor systems are used, then functional reliability is maintained, but manufacturing costs increase
Solution Approach 1:
The three-phase bridge arm converter is designed as a universal component that performs multiple functions: AC-to-DC conversion during charging, DC-to-AC inversion for motor drive, and potential regenerative braking. By manufacturing a single multi-functional unit instead of separate dedicated systems, the patent reduces overall manufacturing costs through economies of scale, shared component procurement, and simplified assembly processes, while maintaining reliability through proven converter technology adapted for multiple roles.
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 integrated energy conversion apparatus enhances vehicle integration, simplifies the structure layout, reduces costs and volume, and ensures safe isolation between the charging port and high-voltage battery, thereby addressing the limitations of existing technologies.
Implementation Method 1
a primary-side winding of the transformer is connected to an alternating current charging port
Implementation Method 2
A direct current port of the three-phase bridge arm converter is connected to a battery; an alternating current port of the three-phase bridge arm converter is connected to the motor winding
Data Source
AI summary
An energy conversion apparatus, a motor, a power system, and a vehicle are provided. The energy conversion apparatus may integrate a motor drive function by using a three-phase bridge arm converter and a motor winding, and integrate an alternating current charging function by using a two-phase two-bridge-arm converter and a transformer. In this way, the energy conversion apparatus can integrate the charging function and the motor drive function. When the energy conversion apparatus is installed on an electric vehicle, a vehicle integration level can be increased, a structure layout of the electric vehicle can be simplified, and costs and a volume of the electric vehicle can be reduced.