Integrated EV Battery-Inverter Unit to Cut Cables and EMC Issues
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Solution Overview
Problem
The complexity and cost of electric vehicle powertrains are increased by the use of separate battery and inverter components, leading to installation difficulties, reliability issues, and electromagnetic compatibility problems due to numerous cables and components.
Innovation Solution
An integrated device that combines a lithium-ion battery and a three-phase bridge inverter with a single electronic control unit, reducing the number of components and cables, and enabling the device to perform functions of both the Battery Management System and Vehicle Management Unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate battery and inverter components are used, then functional independence and reliability of individual components are improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent combines the battery and inverter into a single integrated device with a unified outer casing, integrating multiple functions (power storage, power conversion, control, and management) into one compact unit. This merging reduces the overall number of components, simplifies installation, and decreases the number of electrical connections required while maintaining the functional independence of each subsystem through internal modular architecture.
2Adaptability or versatility
If separate battery and inverter components are used, then component flexibility and adaptability are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The integrated device is designed as a universal powertrain unit that can be applied to various electric vehicle types (e.g., scooters, bicycles, kick scooters). The device performs multiple functions simultaneously - energy storage, DC-to-AC conversion, battery management, and vehicle control - eliminating the need for separate components and reducing manufacturing and assembly complexity while maintaining adaptability to different vehicle platforms.
3Ease of operation
If numerous cables and connectors are used for separate components, then electrical connectivity and control flexibility are improved, but electromagnetic compatibility problems and reliability issues increase
Solution Approach 1:
By integrating the battery and inverter into a single device, the patent dramatically reduces the number of external cables and connectors required. Internal electrical connections are established through integrated bus bars and printed circuit boards within the unified casing, minimizing external wiring. This reduction in cable quantity directly decreases electromagnetic interference sources and potential failure points while maintaining full control flexibility through internal signal routing.
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 integration simplifies the powertrain, reduces costs, enhances reliability, and minimizes electromagnetic compatibility issues, allowing for easier testing and management of electric vehicle components.
Implementation Method 1
an inverter (e.g. three-phase bridge) adapted to convert the direct voltage output from the battery into an alternating voltage useful for powering the electrical machine
Implementation Method 2
a power supply, which is designed to receive the battery voltage and convert it into a different voltage suitable for supplying the front-end circuit and the electronic control unit
Data Source
Figure 1
AI summary
An integrated device (120) is described for power supplying electric vehicles (100), comprising at least: an outer casing (125), a rechargeable electric battery (130) placed in the outer casing (125), a charging socket (135) associated with the outer casing (125) and adapted to allow charging the electric battery (130), an inverter (160) placed in the outer casing (125) and adapted to convert a DC voltage supplied by the electric battery (130) into an AC voltage, a first electrical connector (170) associated with the outer casing (125) and connectable to an electrical machine (115) to transmit the AC voltage generated by the inverter (160) to the latter, and an electronic control unit (175) placed in the outer casing (125), power supplied by the electric battery (130) and configured to manage the operation of the electric battery (130) and of the inverter (160).