Integrated Motor Controller and Power Converter for Hybrid Vehicles
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Solution Overview
Problem
Mild hybrid vehicle systems face challenges with increased wiring and weight due to the need for larger alternators and batteries, leading to inefficient power conversion and layout limitations, particularly in mild hybrid starter generators (MHSG) with parallel switch configurations.
Innovation Solution
A vehicle power conversion apparatus that integrates a motor controller and power supply, featuring a power converter with an inverter and converter in a single unit, utilizing a switching network with back-to-back switching blocks to manage power transfer between the inverter and converter, allowing for selective operation modes to optimize power distribution and reduce size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If parallel configuration is used for converter switches to handle substantial current, then current handling capability is improved, but device complexity and layout difficulty increase
Solution Approach 1:
The patent merges the converter and inverter into a single integrated power conversion device. The converter switches are combined with inverter switches to form shared switching elements, eliminating the need for separate parallel converter switch configurations. This integration maintains current handling capability while reducing structural complexity and layout difficulty.
2Power
If alternator capacity and battery capacity are increased to meet power demands, then power supply capability is improved, but vehicle weight increases
Solution Approach 1:
The patent integrates the converter and inverter into a single device, reducing the overall weight compared to having separate components. This weight reduction helps offset the need for larger alternator and battery capacities, thereby mitigating the increase in vehicle weight while maintaining adequate power supply capability.
Solution Approach 2:
The integrated power conversion device performs multiple functions: it acts as both a converter (for battery charging/discharging) and an inverter (for AC power generation). This multi-functionality eliminates the need for dedicated separate components, reducing overall system weight while maintaining full power supply capability.
3Adaptability or versatility
If multiple separate power conversion components are used, then functional versatility is improved, but overall system size increases
Solution Approach 1:
The patent combines the converter and inverter into a single integrated device with shared magnetic components and switching elements. This merger maintains all necessary power conversion functions (DC-DC conversion and DC-AC inversion) while significantly reducing the overall system volume compared to using separate components.
Solution Approach 2:
The integrated device serves multiple purposes: it can convert DC from the battery to DC for other systems, convert DC to AC for power generation, and share magnetic components across different operational modes. This multi-functionality preserves functional versatility while minimizing system size.
4Ease of operation
If separate converter and inverter systems are used, then operational independence is improved, but power conversion efficiency decreases
Solution Approach 1:
The patent merges the converter and inverter into a single device with shared magnetic components and control circuits. This integration reduces energy losses associated with separate power conversion stages, improving overall efficiency while maintaining operational independence through coordinated control of the shared switching elements.
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 solution reduces the overall size and enhances efficiency by integrating power conversion components, eliminates the need for parallel converter switches, and improves power conversion efficiency by distinguishing between large-power and 12V power supply operations.
Implementation Method 1
a switching network configured to perform a power control between the converter and the inverter
Implementation Method 2
The inverter may be configured to supply alternating current (AC) power to the driving motor
Implementation Method 3
the converter may be configured to convert the AC power into direct current (DC) power
Data Source
AI summary
A vehicle power conversion apparatus is provided to reduce an overall system size by integrating a motor controller which generates power and a power supply apparatus which converts the power. The vehicle power conversion apparatus includes a driving motor which is connected to an engine and a power converter which selectively converts power in a plurality of modes to generate the power related to an operation of the driving motor. A first battery supplies the power for the conversion or receives the converted power.