Dual-Inverter EV Wiring Layout for Leakage Noise Reduction
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Solution Overview
Problem
Electric vehicles face challenges in reducing leakage noise due to limited underfloor space, making it difficult to install additional filter elements, and requiring coordination between induction motor manufacturers and vehicle control device manufacturers to optimize noise reduction.
Innovation Solution
An electric vehicle control device with two inverters, each controlling a group of induction motors mounted on different bogies, with conductors connecting them in a configuration that ensures the inter-center distance between the conductors is equal to or less than three times the average of their maximum lengths, canceling out magnetic fields and reducing leakage noise without additional filter elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If filter elements such as hollow cores are installed around wiring between inverter and motor to reduce common mode noise, then leakage noise is reduced, but underfloor space is insufficient and device complexity increases
Solution Approach 1:
The invention extracts the noise reduction function from separate filter elements and integrates it into the control device's existing structure. By using the housing and existing wiring pathways as part of the noise reduction mechanism, the patent eliminates the need for additional hollow cores or filter elements that would consume underfloor space.
Solution Approach 2:
The control device's housing and structure serve multiple functions: mechanical protection, mounting support, and electromagnetic shielding for noise reduction. The wiring pathways are designed to simultaneously conduct electricity and minimize common mode noise through their geometric arrangement, making the system multi-functional without requiring separate dedicated components.
2Object-affected harmful factors
If filter elements are installed to reduce leakage noise, then noise reduction is achieved, but designing manpower and adjustment work increase
Solution Approach 1:
The control device is designed to automatically reduce leakage noise through its inherent structural characteristics and wiring arrangement. The system self-regulates common mode noise without requiring external filter elements or manual adjustment, as the geometric configuration of conductors and housing features inherently provide electromagnetic shielding and noise reduction.
Solution Approach 2:
The noise reduction function is merged with the control device's existing structure and wiring system. Rather than adding separate filter elements that require independent design and adjustment, the patent combines electromagnetic shielding, wiring layout optimization, and housing design into a unified integrated system that achieves noise reduction as a byproduct of its normal construction.
3Device complexity
If single inverter controls all induction motors, then device simplicity is maintained, but leakage noise increases due to longer conductor lengths and larger inter-conductor distances
Solution Approach 1:
The patent segments the motor control into multiple independent inverters, each controlling a subset of motors. This segmentation reduces the total conductor length within each inverter-motor group and decreases inter-conductor distances, thereby reducing common mode voltage and leakage noise. The segmentation is implemented by dividing motors into groups based on their physical location on different bogies.
Solution Approach 2:
The patent introduces a new dimension to the control architecture by adding a spatial grouping criterion (bogies) to the inverter-motor assignment. Instead of a single centralized inverter, the system uses multiple inverters distributed according to the physical layout of motors on different bogies, creating a three-dimensional optimization that reduces conductor lengths and inter-conductor distances while maintaining system manageability.
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 configuration effectively reduces or eliminates leakage noise without relying on additional filter elements, simplifying design and adjustment processes by maintaining symmetry in leakage currents and reducing magnetic field-induced voltages in wayside devices.
Implementation Method 1
the first inverter and the induction motors belonging to the first electric motor group are connected to each other by a first conductor, and the second inverter and the induction motors belonging to the second electric motor group are connected to each other by a second conductor. Between each of the first and second inverters and the bogies, a first length is equal to or less than three times an average value of a second length and a third length, the first length being an inter-center distance between the first conductor and the second conductor
Data Source
AI summary
An electric vehicle control device includes a first inverter controlling a first group defined by induction motors, and a second inverter controlling a second group defined by induction motors. The first inverter and the induction motors of the first group are connected to each other by a first conductor. The second inverter and the induction motors of the second group are connected by a second conductor. A first length is equal to or less than three times the average value of a second length and a third length. The first length is an inter-center distance between the first conductor and the second conductor, the second length is the maximum length of a conductor portion of the first conductor in the cross section of the first conductor, and the third length is the maximum length of a conductor portion of the second conductor in the cross section of the second conductor.