Gate Driver Controller for Active Discharge in EV Inverters
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Solution Overview
Problem
Existing electric vehicle power electronics systems require bulky and expensive dedicated active discharge circuits to safely dissipate excess energy, which complicates the circuitry and increases costs.
Innovation Solution
Introducing two new operating modes in the traction inverter circuit to dissipate stored energy through motor winding resistance and power transistor on-state resistance, eliminating the need for additional discharge circuitry by leveraging existing inverter circuit components and a controller to manage the discharge process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated active discharge circuits are used to discharge excess energy from HVESEs, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The inverter circuit is designed to perform multiple functions: normal motor drive operation and active discharge of HVESEs. By using the existing inverter switches and motor windings for discharge, dedicated discharge circuitry is eliminated while maintaining safety functionality.
Solution Approach 2:
The motor windings themselves are used as the discharge path, allowing the system to discharge energy through its own components rather than requiring external discharge circuits. The inverter switches control the discharge process using existing circuit elements.
2Reliability
If dedicated active discharge circuits are used to discharge excess energy from HVESEs, then safety is improved, but manufacturing cost increases
Solution Approach 1:
The inverter circuit is designed to perform multiple functions: normal motor drive operation and active discharge of HVESEs. By using the existing inverter switches and motor windings for discharge, dedicated discharge circuitry is eliminated while maintaining safety functionality.
Solution Approach 2:
The motor winding resistance is used as a disposable dissipation path for the stored energy, converting the energy harmlessly into heat without requiring expensive dedicated discharge resistors or circuits.
3Device complexity
If traditional discharge methods are used, then circuit simplicity is maintained, but discharge speed and efficiency are insufficient
Solution Approach 1:
The inverter switches are controlled dynamically to optimize the discharge process. The controller adjusts switch timing and duration to achieve rapid discharge of HVESEs, transforming the static circuit into a dynamically controllable discharge system.
Solution Approach 2:
The discharge process uses periodic switching of the inverter devices to efficiently transfer and dissipate energy from the capacitors through the motor windings, achieving fast discharge through controlled oscillatory current flow.
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 efficient, faster, and more affordable power discharge without additional circuit complexity, ensuring safe energy dissipation and reducing the risk of damage to the circuit and users.
Implementation Method 1
stored energy is to be transferred from the capacitor to at least a portion of the motor winding inductors via at least one activated power transistor to dissipate a first portion of the stored energy
Implementation Method 2
a second portion of the stored energy is to be transferred from the motor winding inductors to at least one activated power transistor to dissipate the second portion of the stored energy
Data Source
AI summary
A gate driver controller, inverter circuit apparatus, and associated discharge method for electric vehicles are disclosed. An example gate driver controller includes a mode determiner to set a mode of operation of the gate driver. The example device includes a gate driver control to control the gate driver to set the gate driver to: a) on, b) off, or c) generate a pulse width modulation signal. When in a first operating mode and set to on, stored energy is to be transferred from a capacitor to a motor winding inductor via a power transistor activated by the gate driver to dissipate a first portion of the stored energy. When in a second operating mode, a second portion of the stored energy is to be transferred from the motor winding inductor to the power transistor to dissipate the second portion of the stored energy.