Fuel Cell Compressor Motor for Plug-in Hybrid Battery Charging
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Solution Overview
Problem
Fuel cell plug-in hybrid vehicles require a separate on-board charger, which increases costs, weight, and space, and existing solutions either require additional components or extend charge time due to underpowered designs.
Innovation Solution
Utilizing the power electronics and electric motor of the compressor, which is already present for air supply to the fuel cell, for both driving and charging, eliminating the need for a separate charger by leveraging dual-use converter and motor capabilities for three-phase charging without additional measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate on-board charger is installed in the vehicle, then the high-voltage battery can be charged externally, but the vehicle cost, weight, and installation space increase
Solution Approach 1:
The patent applies multi-functionality by enabling the compressor's electric motor to perform dual roles: compressing air for the fuel cell during operation and functioning as a generator/transformer for battery charging during external charging. This eliminates the need for a separate dedicated charger, reducing vehicle weight while maintaining full charging capability.
2Productivity
If the on-board charger is designed for total charging power, then full charging speed is achieved, but the charger becomes large, heavy, and expensive
Solution Approach 1:
The compressor motor is designed to handle both compression tasks and charging tasks at full power capacity. By utilizing the existing motor's full capability for charging during external charging events, the system achieves full charging speed without requiring a separate heavy-duty charger dedicated solely to charging functions.
Solution Approach 2:
The patent merges the charging function with the compressor motor, combining two previously separate functions (compression and charging) into a single component. This consolidation eliminates the need for a separate charger while maintaining full charging power capability.
3Weight of moving object
If the on-board charger is designed for lower power, then cost and weight are reduced, but the charge time is extended
Solution Approach 1:
The system dynamically switches between different operating modes of the compressor motor. During external charging, the motor operates in generator mode to enable rapid power transfer, optimizing charging speed without requiring a permanently oversized charger design. This dynamic operation allows the system to achieve high power transfer only when needed.
4Reliability
If a separate charger with transformer and rectifier electronics is installed, then battery charging is enabled, but device complexity and installation space increase
Solution Approach 1:
The existing compressor motor and its integrated converter are made multi-functional by enabling them to perform charging operations. The converter that originally served only the compression function now also handles rectification and voltage conversion for charging, eliminating the need for separate charger electronics and reducing overall system complexity.
Solution Approach 2:
The patent combines the charging electronics functions (rectifier, converter, control) with the existing compressor control system. By merging these functions into the existing infrastructure, the system reduces device complexity and eliminates redundant components while maintaining full charging capability.
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 approach allows for full charging power without additional components, reducing weight and cost while maintaining efficient energy supply, and prevents corrosion issues during external charging by using existing components for both driving and charging modes.
Implementation Method 1
a compressor (34) which is rotationally connected to a motor (36) and is connected to the cathode side (21) via a supply line (33)
Implementation Method 2
The motor (36) can moreover be used to modify the amplitude of a system voltage and the converter (38) to rectify the system voltage, so that a charging voltage is present across the high-voltage battery (42)
Data Source
AI summary
A fuel cell plug-in hybrid vehicle includes a fuel cell having an anode side and a cathode side with a compressor connected to the cathode side. An electric motor is drive-connected exclusively to the compressor. A converter is connected electrically on one side to the motor and on the other side to a high-voltage battery. A controller switches the vehicle between two different operating states. In a first operating state, the high-voltage battery supplies electrical power to the motor via the converter so that the electric motor drives the compressor. In a second operating state, an electrical voltage is supplied from a power supply system to the motor or to the converter via a power supply line. The motor can modify the amplitude of the system voltage with the modified voltage present across the converter, which converts the voltage into a DC voltage applied across the high-voltage battery.