Integrated Bidirectional DC Chopper Energy Storage for Drive Systems
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Solution Overview
Problem
Existing energy storage devices for electric drive systems, particularly in harsh environments like construction machines and cranes, are complex to connect and require laborious configuration, with components needing adaptation to specific drive systems, and face challenges in withstanding harsh conditions such as dust and vibrations.
Innovation Solution
A plug-and-play energy storage device with a bidirectional DC/DC converter, integrated control unit, and modular design that simplifies connection to the DC voltage circuit, includes a common housing for the DC/DC converter, storage block, and control unit, with pluggable connections and a cooling system for thermal management, and optional warning signals and discharge circuits for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy storage devices are used to save energy in electric drive systems, then energy efficiency is improved, but device complexity and connection complexity increase
Solution Approach 1:
The patent combines the DC/DC converter, control unit, and energy storage device into a single integrated module with a common housing. This merging eliminates the need for separate connections and configurations of individual components, reducing installation complexity while maintaining energy storage functionality for improving energy efficiency in electric drive systems.
Solution Approach 2:
The integrated module serves multiple functions: energy storage, DC/DC conversion, control, and thermal management, all within a single device. This multi-functionality allows the module to be universally applied in various electric drive systems without requiring separate specialized components, thereby reducing connection complexity while achieving energy efficiency improvements.
2Use of energy by moving object
If DC/DC converters are used to manage voltage in energy storage devices, then energy management is improved, but device complexity and configuration effort increase
Solution Approach 1:
The control unit within the integrated module automatically manages the DC/DC converter operation, voltage regulation, and energy storage charging/discharging processes without requiring external configuration or manual intervention. This self-service capability simplifies operation while maintaining effective energy management through intelligent control of the DC/DC conversion processes.
3Adaptability or versatility
If energy storage devices are deployed in harsh environments, then application range is expanded, but reliability and protection requirements increase
Solution Approach 1:
The common housing of the integrated module provides protective enclosure for the internal components (DC/DC converter, control unit, energy storage device), shielding them from harsh environmental conditions such as dust, moisture, and mechanical impacts. This protective housing enables deployment in harsh environments while maintaining reliability of the internal electronic components.
Solution Approach 2:
The cooling circuit acts as an intermediary system that mediates between the heat-generating internal components and the external harsh environment. It provides thermal management and temperature control, protecting the sensitive electronic components from thermal stress while allowing the device to operate in demanding environmental conditions, thus expanding application range while maintaining reliability.
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
Simplifies the connection and operation of energy storage devices, ensures efficient and safe energy storage and release, and withstands harsh conditions, reducing the complexity of cabling and ensuring reliable performance in demanding environments.
Implementation Method 1
the at least one storage block (7) and/or the DC/DC converter (8) are connected to a cooling circuit (100) inside the common housing (10)
Implementation Method 2
which has coolant connections (14) on the housing (10) for connection to an external cooling circuit in order to be able to conduct the heat that gets into the coolant out of the storage block (7) and/or the DC/DC converter (8) out of the housing (10)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates generally to drive systems having at least one electric motor, which can be powered by means of power electronics that can be connected to a voltage source via a DC voltage circuit, and an energy storage apparatus for the temporarily storing energy fed back from the electric motor. In this case, the invention relates particularly to an energy storage apparatus for such a drive system, having at least one electrical storage block, a DC chopper for connecting said DC voltage circuit to the internal voltage circuit of the storage block, and a control unit for controlling the DC chopper. According to the invention, the energy storage apparatus is distinguished in that the DC chopper is in bidirectional form, the control unit has delivery and feed control means for actuating the DC chopper both for delivering and for feeding current from and to the storage block, wherein said DC chopper, the storage block and the control unit are combined to form an energy storage unit with a common housing that holds said components and the outside of which is provided with 2 connections for connection to the DC voltage circuit.