Electric Compressor Residual Voltage Interruption During Connector Detachment
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Solution Overview
Problem
Existing electric compressors in vehicles face the risk of electric shock accidents due to residual voltages after detachment of the high voltage connector during high-speed operations, posing a safety hazard during inspection and repair work.
Innovation Solution
A residual voltage controller is introduced, comprising first and second voltage controllers connected in series and parallel between the high voltage connector and the inverter part, utilizing switching elements and resistance to promptly interrupt and discharge residual voltages, ensuring safe detachment and stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high voltage connector is detached during high-speed operation, then the power supply is interrupted, but residual voltage remains in the motor part causing electric shock hazard
Solution Approach 1:
The patent applies preliminary action by detecting the detachment state of the high voltage connector before residual voltage becomes hazardous. The controller detects connector detachment and activates voltage interruption switches and discharge resistors proactively to prevent electric shock accidents, rather than waiting for voltage to naturally decay
Solution Approach 2:
The patent introduces voltage interruption switches and discharge resistors as intermediary components between the motor part and the external environment. These intermediaries actively manage residual voltage by providing controlled discharge paths, mediating the hazardous voltage decay process to protect operators during inspection and repair work
2Object-affected harmful factors
If a resistance with great capacity is provided at DC input end to discharge continuously, then residual voltage is reduced, but device complexity and energy consumption increase
Solution Approach 1:
The patent applies dynamics by making the discharge circuit configurable rather than fixed. The controller dynamically switches between different discharge paths using voltage interruption switches and selectable resistors (R1, R2, R3), allowing the system to adapt discharge resistance based on operational state and voltage levels, optimizing both safety and energy efficiency
Solution Approach 2:
The patent changes resistance parameters dynamically by providing multiple resistor options (R1, R2, R3) with different capacity values. The controller can select appropriate resistance values based on the detected voltage level and operational context, allowing optimization of discharge speed versus energy consumption without requiring a single high-capacity resistor that would continuously consume energy
3Power
If the inverter operates as inductive load at high speed, then power output is maintained, but residual voltage persists longer causing safety delay
Solution Approach 1:
The patent extracts the harmful inductive energy from the motor part by providing dedicated discharge paths through the voltage interruption switches and discharge resistors. When connector detachment is detected, the switches isolate the inverter circuitry and route residual voltage through resistors R1-R3, actively removing stored energy rather than relying on natural decay
Solution Approach 2:
The patent applies preliminary anti-action by preemptively activating voltage interruption switches and discharge resistors when connector detachment is detected. This counteracts the natural tendency of inductive loads to maintain voltage, actively opposing the residual voltage generation to accelerate voltage decay and protect operators during inspection and repair work
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 effectively prevents electric shock accidents by rapidly interrupting residual voltages, facilitating safe inspection and repair work by ensuring the voltage drops to safe levels before detachment, thereby enhancing operational safety.
Implementation Method 1
voltage controllers connected between the high voltage connector and the inverter part in each different direction to interrupt a residual voltage of the motor part
Implementation Method 2
utilizing switching elements and resistance to promptly interrupt and discharge residual voltages
Data Source
AI summary
A residual voltage controller and an electric compressor including the same, which aim to prevent an electric shock or an accident caused by detachment of a high voltage connector through safe interruption of a residual voltage using a plurality of switching elements. The residual voltage controller includes a high voltage connector having an interlock, an inverter part configured to receive power from the high voltage connector, a motor part electrically connected to the inverter part to be controlled, and voltage controllers connected between the high voltage connector and the inverter part in each different direction to interrupt a residual voltage of the motor part when detachment of the high voltage connector is performed before a normal stop signal.