Electric Vehicle Controller Abnormal Condition Protection
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Solution Overview
Problem
In electric vehicles, external forces such as collisions can cause energy stored in the power storage unit to be discharged, leading to heat and electromagnetic damage to the controller and vehicle.
Innovation Solution
An electric-vehicle controller is designed with a control unit that detects abnormal circumstances, such as excessive acceleration or external impacts, and immediately stops the DC-to-DC converter operation, disconnecting the power storage unit to prevent energy discharge and minimize damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the power storage unit stores large energy to drive the electric vehicle, then the energy supply capability is improved, but the risk of heat and electromagnetic damage from accidental discharge increases
Solution Approach 1:
The patent divides the control system into multiple independent protective layers: a control unit that monitors abnormal circumstances, a switching element that isolates the power storage unit, and a bypass circuit that safely dissipates energy. This segmentation ensures that the large energy storage capability is maintained while multiple independent mechanisms prevent catastrophic discharge.
Solution Approach 2:
The patent implements preliminary protective actions by equipping the system with a control unit that continuously monitors for abnormal circumstances before they can cause damage. The switching element is pre-positioned to immediately disconnect the power storage unit upon detecting anomalies such as collisions or overheating, preventing the harmful discharge before it occurs.
2Loss of energy
If the controller integrates power storage unit with inverter to utilize regenerative energy, then the energy efficiency is improved, but the vulnerability to external impact damage increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating protective mechanisms that activate prior to catastrophic failure. The control unit continuously monitors for external impacts and abnormal circumstances, and the switching element stands ready to immediately isolate the power storage unit upon detecting collisions or other external threats, cushioning the system against potential damage before it occurs.
Solution Approach 2:
The patent introduces the switching element as an intermediary between the power storage unit and the rest of the system. This intermediary can rapidly disconnect the power storage unit from the inverter and other components when external impacts or abnormal circumstances are detected, protecting the integrated system while maintaining the energy efficiency benefits of the integration during normal operation.
3Productivity
If the DC-to-DC converter operates continuously to manage power storage, then the power management capability is improved, but the risk of energy discharge during abnormal circumstances increases
Solution Approach 1:
The patent applies dynamics by making the power management system adaptable to changing conditions. The control unit continuously monitors the operational state and can dynamically switch between normal power management mode and protective isolation mode. The switching element enables rapid transition from continuous DC-to-DC converter operation to isolated power storage, allowing the system to optimize power management during normal operation while preventing harmful discharge during abnormal circumstances.
Data Source
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AI summary
There is obtained an electric-vehicle controller that prevents energy stored in a power storage unit from being discharged in the case where a collision, a derailment, or breakage of an overhead line occurs. The electric-vehicle controller is provided with a DC-to-DC converter one terminal pair of which is connected to the DC power source side of the inverter, a power storage unit that is connected to the other terminal pair of the DC-to-DC converter and stores electric power, a switch provided between the power storage unit and the DC-to-DC converter, and a control unit that opens the switch in the case where abnormal circumstances may occur or have occurred.