Hybrid Multi-Chip Inverter Module for Variable Current Efficiency
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Solution Overview
Problem
Existing power inverter systems in electric vehicles face challenges in achieving efficient and reliable performance across varying current draw scenarios, as different power modules are more efficient at either lower or higher current levels.
Innovation Solution
A system and method for controlling a power inverter in a vehicle using a single multi-chip power module that combines silicon type devices and wide bandgap devices, allowing these devices to be aligned in parallel and operated independently or in parallel, with each device type forming multiple functional switches under independent electrical control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single type of power module is used in the inverter, then the system structure is simple, but the efficiency is compromised at certain current levels
Solution Approach 1:
The power module is segmented into multiple independent semiconductor devices (first device type and second device type) that can be independently controlled. Each device type is optimized for specific current ranges, allowing the system to segment the operating conditions and select the most efficient device for each scenario.
Solution Approach 2:
The inverter dynamically selects and switches between different semiconductor devices based on real-time current draw conditions. The controller adjusts which devices are active and in what configuration (parallel, series, or independent) to optimize efficiency across varying operating conditions.
2Loss of energy
If different power modules are used for different current levels, then the efficiency is improved, but the device complexity increases
Solution Approach 1:
Multiple semiconductor devices of different types are merged into a single integrated power module. This consolidation allows the system to access multiple device types for optimal efficiency while maintaining a unified module structure that reduces overall system complexity compared to using separate modules.
Solution Approach 2:
The power module is designed with universal functionality to operate in multiple configurations (parallel, series, independent control) depending on the operating conditions. This multi-functionality allows a single module to replace what would traditionally require multiple specialized modules.
3Loss of energy
If multiple semiconductor devices are controlled independently, then the efficiency across current levels is optimized, but the control complexity increases
Solution Approach 1:
The controller is pre-programmed with optimization algorithms that automatically determine the optimal device configuration based on the current draw level. This preliminary preparation of control strategies simplifies real-time decision-making and reduces the perceived control complexity during operation.
Solution Approach 2:
The control system continuously monitors the current draw and efficiency metrics, then adjusts the active devices and their configuration in real-time. This feedback mechanism automates the optimization process, reducing the need for complex manual control while maintaining peak efficiency across varying conditions.
Data Source
AI summary
A system and method for receiving, at a multi-chip power module, multiple electronic control signals by one or more semiconductor devices of a first device type configured in parallel to one or more semiconductor devices of a second device type. The one or more semiconductor devices of the first device type and the one or more semiconductor devices of the second device type form a plurality of functional switches. The functional switches independently change states, in response to the plurality of electronic control signals. The one or more semiconductor devices of the first device type are configured to be electrically controlled for use independently and de-coupled, or in parallel, with the one or more semiconductor devices of the second device type.