DC Link Brake Actuator H-Bridge for Balanced Energy Dissipation

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Solution Overview

Problem

Current brake actuators in vehicle drive systems convert electrical energy into heat inefficiently, leading to increased battery wear and reduced lifespan due to unbalanced energy conversion and minimum switch-on time dependencies.

Innovation Solution

A brake actuator arrangement utilizing four semiconductors in an H-bridge configuration with a resistor, operating with a 50% duty cycle and phase offset, allowing precise control of energy conversion into heat independent of minimum switch-on time and DC voltage levels, thereby reducing battery stress and extending its lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a series connection of switch and resistor is used for braking, then the structure is simple, but the energy conversion efficiency is low and battery wear increases

Engineering Contradiction:
Improvestructural simplicityVSAvoidenergy conversion efficiency
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent divides the single switching function into four semiconductor switches arranged in an H-bridge configuration. Each semiconductor can independently control current flow through the braking resistor, enabling precise energy management and improving conversion efficiency while maintaining structural clarity through modular segmentation.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces dynamic control through pulse-width modulation (PWM) of the four semiconductor switches. By dynamically adjusting the duty cycle and switching sequences, the system optimizes energy conversion efficiency across varying operating conditions, transforming the static switching approach into a dynamically adaptable system.

Inventive Principle:
Principle #15Dynamics

2Ease of operation

If minimum switch-on time is required for semiconductors, then the control is simplified, but the energy conversion precision is reduced

Engineering Contradiction:
Improvecontrol simplicityVSAvoidenergy conversion precision
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent employs periodic switching of the four semiconductor devices in complementary pairs with 50% duty cycle. This periodic action eliminates the need for minimum switch-on time constraints while maintaining control simplicity, as the balanced switching pattern naturally manages current flow without requiring extended pulse widths.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent changes the control parameters by operating all four semiconductors at a fixed 50% duty cycle with phase shifts, rather than using variable duty cycles with minimum time constraints. This parameter transformation enables precise energy conversion control while simplifying the control logic through symmetric operation.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If unbalanced energy conversion occurs in the intermediate circuit, then the battery experiences increased stress, but the system operation continues

Engineering Contradiction:
Improvesystem continuityVSAvoidbattery lifespan
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent implements feedback control by continuously monitoring the intermediate circuit voltage and using the four semiconductor switches to actively balance energy conversion. The control system adjusts switching patterns based on real-time conditions, preventing unbalanced energy conversion and reducing battery stress while ensuring continuous reliable operation.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent introduces the H-bridge circuit with four semiconductors as an intermediary between the intermediate circuit and the braking resistor. This intermediary structure enables precise control of energy dissipation, balancing the energy flow and protecting the battery from excessive stress while maintaining system continuity.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Measurement precision

If four semiconductors in H-bridge configuration are used, then energy conversion precision is improved, but the device complexity increases

Engineering Contradiction:
Improveenergy conversion precisionVSAvoidcircuit configuration complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses asymmetric switching patterns of the four semiconductor devices in the H-bridge configuration. By applying phase shifts and complementary switching to different semiconductor pairs, the system achieves precise energy conversion control while managing the inherent complexity through deliberate asymmetric operation rather than symmetric simplicity.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The four semiconductor switches in the H-bridge configuration serve multiple functions simultaneously: they control current direction, regulate power dissipation, balance intermediate circuit voltage, and protect the battery. This multi-functionality justifies the increased device complexity by consolidating multiple control tasks into a single integrated circuit structure.

Inventive Principle:
Principle #6Universality (Multi-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

This solution enables precise control of energy conversion, reduces battery wear, and increases the lifespan of semiconductors and batteries by evenly distributing load and minimizing uneven aging, ensuring safe energy conversion and protection against overloading.

Implementation Method 1

A resistor in the braking unit is used for the heat conversion. If the intermediate circuit voltage exceeds a predetermined limit, the switch closes and causes a current to flow through the resistor, thereby converting electrical energy into heat.

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the semiconductors each have a semiconductor switch configured to switch a current in a first current direction through the respective semiconductor, wherein the semiconductors each have a diode configured to conduct a current through the respective semiconductor in a current direction opposite to the first current direction

Methodology Applied
Scientific EffectSemiconductor switching:

Data Source

PatentEP4321366A1Brake actuator for the intermediate circuit of a drive system
Publication Date: 2024.02.14 MERITOR ELECTRIC VEHICLES GERMANY GMBH
  • EP4321366A1 patent drawingFigure 1
  • EP4321366A1 patent drawingFigure 2
  • EP4321366A1 patent drawingFigure 3

AI summary

The invention relates to a brake actuator arrangement (1) for a DC link (2). To improve the brake actuator arrangement (1), it is proposed that the DC link (2) be directly electrically connected to one of the terminals (31) of a battery (3), wherein the brake actuator arrangement comprises four semiconductors (51, 52, 53, 54) arranged in a bridge circuit, a resistor (5) being arranged in the bridge branch, and wherein the semiconductors (51, 52, 53, 54) are configured to operate at a duty cycle of 50%. The invention further relates to a drive system (10) with such a brake actuator arrangement (1), wherein the drive system (10) comprises a regenerative electric machine (6). The invention further relates to a vehicle (100) with such a drive system (10), wherein the drive system (10) is configured to feed the electrical energy generated during braking of the vehicle (100) back into the DC link (2).The invention further relates to a method for controlling semiconductors (51, 52, 53, 54) of such a brake actuator arrangement (1), wherein in a first operating module the semiconductors (51, 52, 53, 54) are switched with a duty cycle of 50%, wherein the power to be converted into heat by the brake actuator arrangement (1) is controlled or regulated by means of a switching delay.