Dual Motor Inverter Charger Integration With Bi-Directional PFC
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Solution Overview
Problem
Dual motor inverter systems with integrated AC-to-DC onboard chargers face efficiency and packaging constraints, affecting performance and thermal management.
Innovation Solution
A dual motor inverter system with integrated AC-to-DC onboard chargers featuring bi-directional power factor correction and isolated DC-DC converter circuits, allowing for streamlined designs and reduced component count, facilitating unified fluid cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate AC-to-DC onboard chargers are used for each motor inverter system, then charging functionality is provided, but system volume and component count increase
Solution Approach 1:
The patent combines two separate AC-to-DC onboard charger circuits into a single integrated charger circuit that serves both motor inverter systems. The integrated charger shares common components including AC input filtering, rectification, and DC output stages, while using switching mechanisms to distribute power to either or both motor systems as needed. This merging reduces overall system volume and component count while maintaining full charging capability for both motors.
Solution Approach 2:
The integrated onboard charger is designed with multi-functionality to serve dual purposes: it can charge the first motor inverter system, the second motor inverter system, or both simultaneously. The charger incorporates switching circuitry and control logic that enables it to adapt its output configuration based on which motor system requires charging, making a single charger unit universal for both motor systems rather than requiring dedicated chargers for each.
2Volume of stationary object
If integrated AC-to-DC onboard chargers are implemented, then system volume is reduced, but thermal management complexity increases
Solution Approach 1:
The patent integrates the thermal management systems into the unified charger architecture, combining heat dissipation pathways and cooling mechanisms that serve both motor inverter systems. The integrated design allows shared thermal management components such as heat sinks, cooling channels, or liquid cooling loops to handle thermal loads from both chargers and motor systems, reducing overall thermal management complexity despite the consolidated design.
3Loss of energy
If bi-directional power factor correction circuit is used, then power efficiency is improved, but circuit complexity increases
Solution Approach 1:
The bi-directional power factor correction (PFC) circuit is designed as a universal component that performs multiple functions: it corrects power factor for AC input, enables bi-directional power flow for charging and discharging operations, and provides voltage regulation. By integrating these functions into a single bi-directional PFC stage rather than separate unidirectional PFC circuits, the patent reduces overall circuit complexity while maintaining improved power efficiency through active power factor correction.
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
Enhances system performance by reducing size and weight, improving efficiency, and simplifying thermal management while maintaining operational reliability.
Implementation Method 1
the first onboard charger circuitry, the first ISC circuitry, and the second onboard charger circuitry may form a bi-directional power factor correction (PFC) circuit
Implementation Method 2
the second motor inverter system and the onboard charger circuitry may form a bi-directional isolated DC-DC converter circuit
Data Source
AI summary
Systems are provided for integrating AC-to-DC onboard chargers into dual motor inverter systems. In one example, a system may include a first motor inverter system having a first electric a first motor inverter system having a first electric motor circuitry and a first inverter system controller (ISC) circuitry and a second motor inverter system having a second electric motor circuitry and a second ISC circuitry. The system may also include a first onboard charger circuitry electrically connected to the first electric motor circuitry and electrically connected to the first ISC circuitry, and a second onboard charger circuitry electrically connected to the first ISC circuitry. The first onboard charger circuitry, the first ISC circuitry, and the second onboard charger circuitry may form a bi-directional power factor correction circuit.