Integrated Fuel Cell Compressor Drive Circuit and Energy Supply Unit
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Solution Overview
Problem
In fuel cell vehicles, the energy supply and control unit for the fuel cell compressor requires a significant installation space due to multiple functional sub-units, leading to increased weight and reduced performance, and existing solutions are not cost-effective or easy to install, maintain, and replace.
Innovation Solution
An integrated energy supply and control unit with a DC/DC converter and inverter housed in a common compact housing, sharing interfaces and components to minimize space and weight, while allowing simultaneous power supply to both the drive motor and compressor motor, with separate interfaces for direct current and alternating current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate functional sub-units are used for energy supply and control, then functional completeness is ensured, but installation space and weight increase
Solution Approach 1:
The patent combines the DC/DC converter and inverter into a single integrated housing, merging two separate functional sub-units into one compact device. This reduces the overall installation space while maintaining both voltage conversion functions simultaneously, directly resolving the contradiction between functional completeness and space efficiency.
Solution Approach 2:
The integrated housing serves multiple functions: it houses both the DC/DC converter and inverter, provides common cooling for both components, and offers a unified control interface. This multi-functionality approach maintains complete energy supply and control capabilities while minimizing the space required for installation.
2Adaptability or versatility
If multiple separate functional sub-units are used for energy supply and control, then functional completeness is ensured, but weight increases
Solution Approach 1:
By merging the DC/DC converter and inverter into a single housing with shared structural components, cooling systems, and control interfaces, the patent eliminates redundant weight from separate mounting structures, independent cooling systems, and duplicate control electronics, thereby reducing overall weight while preserving full functionality.
3Reliability
If multiple separate functional sub-units are used for energy supply and control, then functional independence is maintained, but device complexity increases
Solution Approach 1:
The integrated housing contains clearly segmented functional zones for the DC/DC converter and inverter, with dedicated cooling channels and control interfaces for each subsystem. This segmentation maintains functional independence and reliability while reducing the number of external components and interconnections required.
4Ease of repair
If multiple separate functional sub-units are used for energy supply and control, then individual maintenance is possible, but installation and maintenance effort increases
Solution Approach 1:
The housing is designed with separable sections and accessible interfaces that allow technicians to maintain individual subsystems (DC/DC converter or inverter) without dismantling the entire assembly. This segmentation enables individual maintenance while the integrated design reduces overall installation complexity compared to multiple separate units.
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 design significantly reduces installation space and weight, enhances efficiency, and simplifies installation, replacement, and maintenance by integrating power supply and control functions within a single, compact unit, reducing the need for multiple components and interfaces.
Implementation Method 1
A DC/DC converter (step-up converter) is to be provided for converting the output voltage of the fuel cell unit
Implementation Method 2
the output of the DC/DC converter is connected to the input of the inverter... Direct current (or DC voltage) being provided on the former and alternating current on the latter
Implementation Method 3
The necessary voltage conversion generates large amounts of heat, the dissipation of which is a major challenge in a confined space
Data Source
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AI summary
The invention relates to a power supply and control unit (1) for supplying a drive circuit, in particular a traction drive circuit, and a fuel cell compressor via separate interfaces (6, 7), comprising: - a DC/DC converter (10) with a fuel cell input interface (11), - an inverter (20), - a drive circuit interface (7) for connection to a drive circuit (36), and - a compressor motor interface (6) for connection to a compressor motor (3) of a fuel cell compressor, wherein the output (12) of the DC/DC converter (10) is connected to the input (21) of the inverter (20) and to the drive circuit interface (7), and wherein the output (22) of the inverter (20) is connected to the compressor motor interface (6), and wherein the DC/DC converter (10) and the inverter (20) are housed in a common enclosure (9).