Electric Drive Power Module Switching for Lower Converter Losses
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Solution Overview
Problem
Existing methods for controlling electric drive vehicles with high-rated power electric motors fail to maximize energy efficiency by minimizing power losses in electric and electronic components across various operating conditions.
Innovation Solution
A control method that dynamically switches between using one or both power modules and axles of electric motors and converters based on current and torque thresholds, combined with cyclical switching to distribute wear and heat, using control units to optimize power distribution and minimize losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If both power modules are used simultaneously to handle high power demands, then the power delivery capability is improved, but the total electrical power losses increase
Solution Approach 1:
The control system dynamically switches between using one or both power modules based on real-time operating conditions. The controller monitors current draw and torque requirements, activating only the necessary number of modules to meet demand while minimizing energy losses. This dynamic adaptation resolves the contradiction by adjusting system configuration rather than maintaining a fixed dual-module setup.
Solution Approach 2:
The system changes operational parameters by switching between different module configurations (one module active vs. both modules active) based on operating conditions. By monitoring current thresholds and torque requirements, the controller selects the optimal configuration that delivers required power while minimizing electrical losses, thus resolving the trade-off between power capability and energy efficiency.
2Loss of energy
If one power module is used exclusively to reduce power losses, then energy efficiency is improved, but the maximum power delivery capability is reduced
Solution Approach 1:
The system transitions from a static single-module configuration to a dynamic system that can activate one or both modules based on real-time power demands. When high power is required, both modules are activated; when lower power suffices, only one module operates, thus maintaining efficiency while enabling peak power capability when needed.
Solution Approach 2:
The control system enables the powertrain to universally handle multiple operating scenarios by having the capability to operate with either one or both power modules. This multi-functional approach allows the system to adapt to varying power demands, achieving both efficiency during normal operation and maximum power delivery when required.
3Loss of energy
If continuous operation with one power module is used to minimize losses, then energy efficiency is improved, but component wear and heat concentration increase
Solution Approach 1:
The control system implements periodic switching between power modules based on operational cycles and wear distribution algorithms. By alternating which module serves as the primary active unit, the system distributes thermal load and mechanical wear across both modules over time, preventing concentration of stress on a single component while maintaining overall efficiency.
Solution Approach 2:
The controller continuously monitors operating conditions, temperature, and module performance metrics to make intelligent decisions about module activation and switching. This feedback mechanism ensures that wear and heat are distributed appropriately while maintaining optimal efficiency, resolving the contradiction between minimizing losses and managing component stress.
4Loss of energy
If complex real-time optimization algorithms are used to minimize power losses, then energy efficiency is improved, but computational resource requirements increase
Solution Approach 1:
The control system applies a simplified optimization approach that considers only the most critical parameters (current draw, torque requirements, basic temperature thresholds) rather than implementing comprehensive real-time optimization of all possible variables. This partial action approach achieves sufficient energy efficiency improvement without requiring excessive computational resources, resolving the contradiction between optimization depth and system complexity.
Data Source
AI summary
A method to control an electric drive vehicle having at least one electric motor and an electronic power converter provided with at least two power modules, which are connected to one another in parallel to power the electric motor together. The control method provides for the steps of: determining an intensity of an electric current to be supplied by the electronic power converter to the electric motor; comparing the desired intensity of the electric current with a threshold value; and always using both power modules to supply the electric current to the electric motor, if the desired intensity of the electric current exceeds the threshold value.