Integrated EV Motor Charging Control Using Shared Motor Coils
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Solution Overview
Problem
Existing electric vehicles (EVs) have redundant components in their electrical drive and charging systems, leading to increased weight and complexity, which reduces travel range.
Innovation Solution
A combined electric control system that integrates the electrical drive and charging systems using a multi-phase electric motor, energy storage device, transistor modules, and a microcontroller to operate in multiple modes, including motoring, charging, and generating AC, thereby reusing motor coils as buck or boost converter inductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate electrical drive system and charging system are provided in EV, then each system can be optimized independently, but system weight and complexity increase due to redundant components
Solution Approach 1:
The patent combines the electrical drive system and charging system into a single integrated control system. The motor controller and charger share common components including transistor modules, inductors (motor coils), current sensors, and a unified microcontroller that manages both motoring and charging operations, thereby reducing redundancy while maintaining independent optimization capabilities
Solution Approach 2:
The motor coils serve dual purposes: functioning as inductors in the charging circuit and as motor windings in the drive system. The transistor modules and current sensors are universally used in both motoring and charging modes, allowing a single system to perform multiple functions without requiring separate dedicated components for each operation
2Adaptability or versatility
If separate electrical drive system and charging system are provided in EV, then each system can operate independently, but system weight increases due to redundant components
Solution Approach 1:
The patent merges the drive and charging systems by eliminating redundant components. The battery pack, transistor modules, inductors, current sensors, and control microcontroller are shared between both systems, reducing the overall component count and system weight while maintaining the capability for independent operation in either motoring or charging mode
3Reliability
If redundant components are provided in electrical systems, then system reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements universal components that serve multiple functions: the motor coils act as inductors for charging and windings for motoring, transistor modules control current in both charging and driving modes, and current sensors monitor electrical parameters across both operations. This multi-functionality reduces the total number of components required, lowering manufacturing costs while maintaining system reliability through shared proven components
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
Reduces system cost, weight, and complexity while maintaining peak current charging and motoring capabilities, and allows the motor to function as an AC generator, enhancing energy efficiency and reducing redundant components.
Implementation Method 1
a multi-phase electric motor having a plurality of motor coils, an energy storage device configured to provide energy to the electric control system, a plurality of transistor modules selectively coupling the electric motor to the energy storage device
Implementation Method 2
a controllable switching device configured to selectively couple the connector to the multi-phase electric motor, and a microcontroller configured to control the switching device to selectively couple the connector to at least one of the motor coils during a detected charging mode
Data Source
AI summary
A rotor assembly and motor having the rotor assembly is described. The rotor assembly includes a rotor core formed from a plurality of rotor sheets, each rotor sheet having a cross section shape defining a plurality of magnet retaining tabs, the magnet retaining tabs defining a magnet receiving gap and at least one magnet shaped to be installed within the magnetic receiving gap.