Integrated Power Electronic Building Block for Automotive Scalability
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Solution Overview
Problem
Current power converter systems in alternative fuel vehicles, such as hybrid and fuel cell vehicles, face challenges in scalability, modularity, and performance due to the complexity of electrical systems and the need for direct current-to-alternating current (DC/AC) inversion, as well as management of multiple voltage sources.
Innovation Solution
The development of a power electronic building block that integrates a power module, AC and DC bus bars, a capacitor assembly, a controller, and a current sensor within a single package, allowing for scalable and modular design with improved thermal management and electrical connectivity, enabling efficient power conversion and management across various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power converters are designed with separate components for DC/AC inversion and voltage source management, then each component can be optimized for its specific function, but the overall system complexity increases and scalability across different applications decreases
Solution Approach 1:
The patent combines the DC/AC inverter and DC/DC converter into a single integrated power electronic building block (PEBB). The inverter section includes DC/AC conversion circuitry while the DC/DC section handles voltage conversion, both within one modular package. This merging reduces system complexity by eliminating the need for separate components while maintaining optimized performance for each function through dedicated circuit designs within the integrated architecture.
Solution Approach 2:
The integrated power electronic building block is designed to perform multiple functions simultaneously - DC/AC inversion for AC motor drive and DC/DC conversion for voltage source management. This multi-functional design enables the same component to serve different purposes in alternative fuel vehicles, reducing overall system complexity while maintaining specialized performance for each function through configurable circuit arrangements.
2Ease of manufacture
If traditional separate-component power converter systems are used, then component design and validation can be simplified for individual parts, but the overall production cost and integration complexity increase
Solution Approach 1:
The power electronic building block is divided into distinct functional sections - an inverter section with DC/AC conversion and a DC/DC section with voltage conversion capability. Each section can be independently designed and validated for its specific function, simplifying the validation process. The segmented design allows modular assembly where validated sections can be reused across different applications, reducing overall production costs through standardized manufacturing processes.
3Adaptability or versatility
If power electronic systems are designed without modular integration, then customization for specific applications becomes easier, but scalability across different vehicle types and applications is limited
Solution Approach 1:
The power electronic building block employs a nested modular architecture where the DC/DC converter section is integrated within the same package as the DC/AC inverter section. This nested design allows the smaller DC/DC module to be housed within or alongside the larger inverter module, creating a compact integrated unit that maintains the flexibility of customized configurations while reducing integration complexity through standardized mechanical and electrical interfaces.
Data Source
AI summary
A power electronic building block includes a housing; a power module mounted within the housing; a controller mounted within the housing and coupled to the power module; a capacitor assembly coupled to the power module and mounted within the housing; an AC bus bar mounted within the housing; and a DC bus bar coupling the capacitor assembly to the power module and mounted within the housing.