Electric Drive Thermal Management via Performance Reduction
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Solution Overview
Problem
High-power electric drive systems face shutdowns due to component overheating, which is undesirable in certain applications, especially when components are installed in different environments, as existing systems only shut down after exceeding safe temperature limits, rendering them unavailable during shutdown periods.
Innovation Solution
An electric drive system with temperature sensors interconnected to a system controller that transmits reduced performance commands when a temperature threshold is reached, allowing the system to continue operating by limiting performance parameters and avoiding complete shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the system allows full performance operation until component temperature exceeds safe limit, then the system achieves maximum performance, but the system shuts down completely when temperature limit is reached, resulting in loss of system availability
Solution Approach 1:
The patent applies partial action by reducing system performance to a level that generates sufficient heat to maintain component temperatures below the safe limit, rather than completely shutting down. The controller dynamically adjusts performance parameters (such as motor speed or power output) to a reduced level that prevents overheating while keeping the system operational, thus maintaining partial functionality instead of full shutdown.
2Reliability
If the system shuts down completely when temperature exceeds safe limit, then the system protects components from damage, but the system becomes unavailable for operation during shutdown periods
Solution Approach 1:
The system dynamically adjusts performance parameters based on real-time temperature feedback from sensors. Rather than using a static shutdown threshold, the controller continuously monitors component temperatures and dynamically modifies operational parameters (such as power output, speed, or load) to maintain temperatures within safe limits while keeping the system operational. This dynamic adjustment allows the system to adapt its performance level to prevent overheating without complete shutdown.
Solution Approach 2:
The patent implements a feedback mechanism where temperature sensors continuously monitor component temperatures and transmit data to the controller. The controller uses this feedback information to adjust performance parameters in real-time, creating a closed-loop control system. When temperature approaches the safe limit, the feedback signal triggers performance reduction; when temperature decreases, performance can be increased again, maintaining continuous operation within safe thermal boundaries.
3Reliability
If the system reduces performance when temperature approaches safe limit, then the system maintains continuous operation and availability, but the system experiences performance degradation
Solution Approach 1:
The patent changes operational parameters (such as motor speed, power output, or load level) dynamically based on temperature conditions. Instead of maintaining a fixed performance level, the system adjusts these parameters to optimize the balance between thermal management and productivity. The controller modifies parameter values to reduce heat generation when temperatures approach limits, thereby maintaining continuous operation while accepting temporary performance reduction as a trade-off for system availability.
Data Source
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AI summary
An electric drive system may include a plurality of heat sensitive components, at least one temperature sensor positioned in or on each of the components and a system controller. The temperature sensors may be interconnected with the system controller to transmit temperature data from their respective heat sensitive components to the system controller. The system controller may be configured to transmit a reduced performance command in the event that a reached-temperature-threshold-limit signal is received from any one or more of the temperature sensors. System shutdown due to over temperature faults may be avoided.