Bidirectional EV Converter Switching Between Drive and Auxiliary Motors

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Solution Overview

Problem

Existing electric vehicles with internal combustion engines lack a cost-effective solution to integrate both travel and work functions, requiring separate interfaces and inverters for different power requirements.

Innovation Solution

A multifunctional converter apparatus with a bidirectional inverter and switch device that connects to both drive and auxiliary motors, allowing for the conversion of direct voltage to alternating voltage and vice versa, enabling simultaneous operation of travel and auxiliary functions in electric vehicles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate interfaces and inverters are used for drive and auxiliary motors, then each motor function can be independently controlled, but the device complexity and cost increase

Engineering Contradiction:
Improveindependent control capabilityVSAvoidnumber of interfaces and inverters
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a universal converter apparatus that can serve both drive motors and auxiliary motors through a single inverter unit. The converter apparatus includes a bidirectional inverter with switching devices that can dynamically connect to different motors based on operational requirements, eliminating the need for separate inverters for each motor function while maintaining independent control capability

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges multiple functions (drive motor control and auxiliary motor control) into a single converter apparatus. The inverter unit combines multiple switching devices and control logic in one integrated system, reducing the overall number of components while preserving the ability to independently control different motor functions

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If a multifunctional converter apparatus is used, then cost and device complexity are reduced, but the switching control complexity increases

Engineering Contradiction:
Improvenumber of invertersVSAvoidswitching control logic
Core Design Contradiction:
Device complexityVSExtent of automation

Solution Approach 1:

The patent employs dynamic switching control where the inverter can change its connection configuration in real-time based on operational mode requirements. The switching devices are controlled dynamically to connect the inverter to either drive motors or auxiliary motors as needed, allowing the system to adapt its internal configuration without physical reconfiguration

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control device monitors the operational state of the vehicle and automatically determines the appropriate switching configuration. The system uses feedback from sensors and control signals to manage the switching between different motor functions, reducing the burden on manual operation while maintaining simplified hardware architecture

Inventive Principle:
Principle #23Feedback

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

The solution provides a cost-saving, compact, and efficient means to supply electrical energy for multiple functions in electric vehicles, extending battery life and enabling parallel operation of travel and auxiliary functions, such as in excavators or street sweepers.

Implementation Method 1

The inverter is designed to convert a direct voltage present at the first connector into an alternating voltage and supply it at the second connector

Methodology Applied
Scientific EffectVoltage conversion (DC to AC): Electromagnetic Induction

Implementation Method 2

a fed-in alternating voltage can be converted into a direct voltage in order to charge the vehicle battery

Methodology Applied
Scientific EffectVoltage conversion (AC to DC): Electromagnetic Induction

Data Source

PatentUS20230271517A1Converter Apparatus for Converting an Operating Current for an Electric Vehicle, Drive Apparatus, and Method for Converting an Operating Current
Publication Date: 2023.08.31 ZF FRIEDRICHSHAFEN AG
  • US20230271517A1 patent drawing
  • US20230271517A1 patent drawing
  • US20230271517A1 patent drawing

AI summary

A converter apparatus for an electric vehicle includes a battery interface for connecting the converter apparatus to a vehicle battery and a bidirectional inverter having a first connector for connecting the inverter to the battery interface and a second connector. The inverter converts a DC voltage applied to the first connector into an AC voltage and to provide this voltage to the second connector. The converter apparatus includes a switch device having a switch connector for connecting the switch device (118) to the second connector, a drive interface for connecting the converter apparatus to a drive motor, and an additional interface for connecting the converter apparatus to an additional motor. The switch device is designed to connect the switch connector to the drive interface or the additional interface using a switching signal.