Heavy-Duty Vehicle Drive Inverter Layout for Brake Power Isolation

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Solution Overview

Problem

In electric machine drive arrangements for heavy-duty vehicles, the integration of braking resistors in parallel with energy storage systems can lead to unintended energy drainage when the circuit breaker does not open or the direct current chopper does not stop conducting, and the motor drive system inverter needs to be dimensioned for maximum brake power, which can be larger than the energy storage capacity.

Innovation Solution

The electric machine drive arrangement includes a rectifier arrangement connected in parallel between the brake arrangement and the motor drive system inverter on the alternating current side, allowing the braking resistor circuit to be separated from the motor drive system inverter and energy storage system, thereby preventing energy drainage and eliminating the need for the motor drive system inverter to be dimensioned for brake power.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the braking resistor is connected in parallel with the energy storage system through the motor drive system inverter, then the braking function can be achieved, but the motor drive system inverter needs to be dimensioned for maximum brake power which exceeds the energy storage capacity

Engineering Contradiction:

Improvebrake powerVSAvoidenergy storage capacity

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

The patent segments the braking function from the motor drive system inverter by introducing a separate rectifier arrangement. The braking resistor circuit is connected to the alternating current side of the rectifier arrangement, allowing independent braking operation without requiring the inverter to handle maximum brake power. This segmentation enables the inverter to be under-dimensioned while maintaining full braking capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rectifier arrangement acts as an intermediary between the braking resistor circuit and the motor drive system inverter. By connecting the braking resistor through the rectifier arrangement on the alternating current side, the patent enables energy dissipation during braking without requiring the inverter to be dimensioned for maximum brake power, thus resolving the contradiction between brake power requirements and energy storage capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the braking resistor is connected in parallel with the energy storage system, then dynamic braking can be achieved, but unintended energy drainage occurs when the circuit breaker does not open or the direct current chopper does not stop conducting

Engineering Contradiction:

Improvebraking functionVSAvoidenergy drainage

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The rectifier arrangement serves as an intermediary that isolates the braking resistor circuit from the energy storage system. By connecting the braking resistor on the alternating current side of the rectifier arrangement rather than directly in parallel with the energy storage system, the patent prevents unintended energy drainage while maintaining reliable braking function. The rectifier arrangement ensures that braking energy is dissipated independently without affecting the energy storage system.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the braking circuit from the energy storage system by introducing a separate rectifier arrangement and connecting the braking resistor to the alternating current side. This segmentation creates independent electrical pathways, allowing the braking function to operate reliably without causing energy drainage from the energy storage system, even when circuit breakers or choppers fail to open properly.

Inventive Principle:

Principle #1Segmentation

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 mitigates the safety issue of energy drainage and allows the motor drive system inverter to be under-dimensioned with respect to maximum brake power, enabling short-term overloading of the electric machine without impacting the inverter's dimensioning, while maintaining torque control and stability.

Implementation Method 1

a rectifier arrangement connected in parallel between the brake arrangement and the motor drive system inverter on the alternating current side of the motor drive system inverter

Methodology Applied

Scientific EffectRectification:

Implementation Method 2

the resistor converts the consume energy into heat and at the same instant braking effect is created

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12206348B2Electric machine drive arrangement for a heavy-duty vehicle

Publication Date: 2025.01.21 VOLVO TRUCK CORP

AI summary

An electric machine drive arrangement for a heavy-duty vehicle. The electric machine drive arrangement comprises a motor drive system inverter with an alternating current side for interfacing with an electric machine. The electric machine drive arrangement comprises a brake arrangement comprising a braking resistor circuit connectable to a control circuit. The electric machine drive arrangement comprises a rectifier arrangement connected in parallel between the brake arrangement and the motor drive system inverter on the alternating current side of the motor drive system inverter.