Integrated Boost Converter and Inverter for Compact Electric Compressor
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Solution Overview
Problem
The installation of a boost converter in a vehicle engine room leads to potential increases in device size due to noise measures, cooling requirements, and the need for separate cables and power systems for low and high voltage systems, making it challenging to maintain a compact design.
Innovation Solution
An electric compressor configuration where the boost converter and inverter are housed on the same circuit board and cooled by a coolant, reducing the need for additional cooling fins and noise mitigation measures, and using wide-band-gap semiconductors to enhance efficiency and reduce device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a boost converter is installed in a vehicle engine room to boost DC voltage from low voltage (12V) to high voltage (300V), then the electric compressor can be driven by low voltage systems, but the device size increases due to noise measures, cooling requirements, and separate cables for low and high voltage systems
Solution Approach 1:
The patent combines the boost converter and inverter into a single integrated unit where the boost converter is housed within the inverter case. This merging eliminates the need for separate housing, cooling systems, and cable management for the boost converter, thereby preventing device size increase while enabling compatibility with low voltage systems
Solution Approach 2:
The inverter is designed to serve dual functions: it acts as both the inverter for converting DC to AC and as the housing/cooling system for the boost converter. The coolant flow path is configured to cool both the inverter and boost converter, making the cooling system universal and eliminating the need for separate cooling fins and noise mitigation measures
2Adaptability or versatility
If the cross-sectional area of energized members is increased to handle high current (300A) for 12V low voltage operation, then the electric compressor can be driven by low voltage systems, but the inverter size increases making it difficult to install in the engine room
Solution Approach 1:
The boost converter is integrated within the inverter case, combining two power conversion functions into one compact unit. This eliminates the need for separate housing and reduces the overall footprint, allowing the inverter to handle high current operations without increasing installation space requirements
3Adaptability or versatility
If a boost converter is newly installed in the vehicle, then low voltage can be boosted to high voltage, but additional cooling fins and noise mitigation measures are required increasing device complexity
Solution Approach 1:
The boost converter is housed within the inverter case, merging two separate systems into one. The inverter's existing cooling system is configured to also cool the boost converter, eliminating the need for separate cooling fins and noise mitigation measures, thereby reducing device complexity while maintaining voltage boosting capability
4Reliability
If separate cables and power systems are provided for low voltage and high voltage systems, then the boost converter can function properly, but the device size increases
Solution Approach 1:
The boost converter and inverter are integrated into a single unit with unified housing and cooling systems. This merging reduces the need for separate cable management and power system components, thereby maintaining reliable power conversion while reducing overall device size
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 configuration prevents the device size from increasing, reduces accessory parts, and enhances cooling and noise management, allowing for a more compact and efficient electric compressor design.
Implementation Method 1
a boost converter configured to boost a voltage output from a direct current power supply
Implementation Method 2
an inverter configured to convert the power boosted by the boost converter to an alternating current power
Implementation Method 3
a motor configured to rotate a compressor using the alternating current power output from the inverter
Implementation Method 4
cooled by a coolant flowing into the compressor
Implementation Method 5
fins and the like for cooling the boost converter are required to be newly provided
Data Source
AI summary
An electric compressor comprises: a boost converter configured to boost a voltage output from a direct current power supply; an inverter configured to convert the power boosted by the boost converter to an alternating current power; and a motor configured to rotate the electric compressor using the AC power output from the inverter. In the electric compressor, the boost converter and the inverter are provided on the same circuit board, housed in the same inverter case, and cooled by a coolant flowing into the electric compressor. The electric compressor is thereby obtained in which the device size can be prevented from increasing even when the boost converter configured to boost a low voltage from the DC power supply is installed.