DC-link Capacitor Discharge Module Integration
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Solution Overview
Problem
Existing solutions for vehicles driven by electric motors do not adequately address the risk posed by high-voltage DC link capacitors during accidents, as they can store charge and act as a high-voltage source, endangering occupants and others, despite efforts to discharge the battery system.
Innovation Solution
A DC link capacitor design with a receptacle for a discharge module, protected by a grid structure of foil coils and conductive projections that short-circuit in case of deformation, ensuring safe discharge even if the discharge module is deformed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery system is discharged manually or automatically after an accident, then the battery system can be safely discharged, but the DC link capacitor remains charged and continues to pose a high-voltage danger
Solution Approach 1:
The discharge module is integrated directly into the DC link capacitor housing, combining the discharge function with the capacitor structure. This ensures that the discharge mechanism remains with the capacitor even if separated from the battery system, enabling independent discharge of the capacitor after an accident.
Solution Approach 2:
A discharge circuit with discharge resistor and switch is pre-installed within the DC link capacitor. The discharge switch is connected to triggerable elements that can be activated by accident signals, enabling immediate discharge of the capacitor without requiring external intervention or separation from the battery system.
2Reliability
If the discharge module is integrated into the DC link capacitor, then the discharge module is protected from deformation, but the connecting line between discharge module and DC link capacitor can be severed by accidental deformation
Solution Approach 1:
The discharge module is integrated directly into the DC link capacitor housing, combining the discharge function with the capacitor structure. This ensures that the discharge mechanism remains with the capacitor even if separated from the battery system, enabling independent discharge of the capacitor after an accident.
3Reliability
If the discharge module is separated from the DC link capacitor and integrated into the battery system, then the discharge module is protected from deformation, but the connecting line to the DC link capacitor can be severed preventing discharge
Solution Approach 1:
The discharge module is integrated directly into the DC link capacitor housing, combining the discharge function with the capacitor structure. This ensures that the discharge mechanism remains with the capacitor even if separated from the battery system, enabling independent discharge of the capacitor after an accident.
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 DC link capacitor effectively protects the discharge module from deformation and ensures instantaneous discharge of the capacitor, enhancing safety by preventing high-voltage risks post-accident, even if the module becomes inoperable.
Implementation Method 1
The DC link capacitor (20) comprises a jacketing (30) enclosing the foil coils (21) with several inwardly extending projections (32) comprising an electrically conductive material or consisting of an electrically conductive material
Data Source
AI summary
A DC link capacitor for a vehicle driven by an electric motor, assembly with a DC link capacitor and a vehicle driven by an electric motor with such an assembly.