Quick Discharge Resistor Control Circuit Integration

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Solution Overview

Problem

Existing electric power converters in vehicles face challenges in quickly discharging accumulated electric charge during emergency situations due to the high resistance value of discharge resistors, which complicates assembly and increases the number of parts and man-hours required.

Innovation Solution

Incorporating a quick discharge resistor with a smaller resistance value and a discharge control circuit on a single circuit board, allowing for controlled current flow during emergencies while minimizing the number of parts and reducing assembly time by integrating the discharge control circuit with the semiconductor control circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a quick discharge resistor with smaller resistance value is added to enable emergency discharge, then the discharge speed is improved, but the number of parts and device complexity increase

Engineering Contradiction:

Improvedischarge speedVSAvoidnumber of parts

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The discharge control circuit is integrated onto the existing circuit board that already contains the semiconductor control circuit, merging multiple control functions into a single board. This eliminates the need for separate discharge control hardware and reduces the overall number of parts while maintaining the quick discharge capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board is designed to serve multiple functions: it hosts both the semiconductor control circuit for normal operation and the discharge control circuit for emergency situations. The circuit board universally handles both regular control tasks and emergency discharge control, eliminating the need for dedicated separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If a separate discharge control circuit is provided for the quick discharge resistor, then the current control capability is improved, but the assembling man-hours and manufacturing complexity increase

Engineering Contradiction:

Improvecurrent control capabilityVSAvoidassembling man-hours

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The discharge control circuit is merged with the semiconductor control circuit on the same circuit board, combining multiple control functions into a single integrated unit. This reduces the number of separate components that need to be assembled and connected, thereby reducing assembling man-hours and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board is segmented into different functional regions: one area hosts the semiconductor control circuit while another area hosts the discharge control circuit. This segmentation allows for modular design and simplified assembly while maintaining the control capability for both normal operation and emergency discharge.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the discharge control circuit is provided on a separate circuit board, then the control function is improved, but the body size and connecting means complexity increase

Engineering Contradiction:

Improvecontrol functionVSAvoidbody size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The discharge control circuit is merged onto the existing circuit board that already contains the semiconductor control circuit. This consolidation eliminates the need for a separate circuit board, thereby reducing the overall body size and simplifying the connecting means between components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board is designed as a universal platform that accommodates both the semiconductor control circuit and the discharge control circuit. This multi-functional board eliminates the need for additional separate boards and connections, reducing the overall volume of the electric power converter.

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

Enables quick electric discharge in emergency situations while reducing the overall size and assembly time of the electric power converter, preventing an increase in parts and simplifying the assembly process.

Implementation Method 1

a quick discharge resistor for discharging an electric charge accumulated in the capacitor

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

a cooler that cools the semiconductor module

Methodology Applied

Scientific EffectHeat Transfer: Heat Exchanger

Data Source

PatentUS9219425B2Electric power converter

Publication Date: 2015.12.22 DENSO CORP

AI summary

An electric power converter includes a semiconductor module that has a semiconductor element therein, a cooler that cools the semiconductor module, a circuit board provided with a semiconductor control circuit that controls the semiconductor module, a capacitor electrically connected to the semiconductor module, and a quick discharge resistor for discharging an electric charge accumulated in the capacitor. The circuit board is provided with a discharge control circuit that controls a current that flows into the quick discharge resistor. The semiconductor module, the cooler, the capacitor, and the quick discharge resistor are disposed on one major surface of the circuit board.