Integrated Power Module for Transport Refrigeration
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Solution Overview
Problem
Transport refrigeration units on vehicles face complexity in harness connections and incompatibility between battery and fuel-powered systems, leading to operational and maintenance challenges due to complex wiring and component incompatibilities.
Innovation Solution
An electrical power module device with DC buck and boost modules, along with a control module, that can step-down or step-up voltage as needed, and includes AC/DC conversion modules to provide flexible power management, integrating with a transport refrigeration unit to simplify wiring and ensure compatibility across different power platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate power devices and inverters are used for different components in the transport refrigeration unit, then each component can be driven independently, but the harness connections become very complex and occupy large space
Solution Approach 1:
The patent combines multiple power devices (DC-DC converter, inverter, charger) into a single integrated power module. This merging eliminates the need for separate harness connections to each individual device, significantly reducing wiring complexity and installation space while maintaining independent control of compressor, fan, and heater through the unified power management system.
Solution Approach 2:
The integrated power module serves multiple functions simultaneously: it acts as a DC-DC converter for voltage regulation, an inverter for AC power generation, and a charger for battery management. This multi-functionality allows a single device to replace multiple separate components, reducing harness connections while maintaining operational independence of various refrigeration unit components.
2Adaptability or versatility
If different power sources (battery or fuel generator) are used in transport vehicles, then flexibility in vehicle power options is achieved, but the transport refrigeration unit becomes incompatible with certain power platforms due to harness connection differences
Solution Approach 1:
The power module is designed with universal input capabilities that can accept power from either battery or fuel generator sources. The integrated architecture with multi-functional power conversion circuits enables the same refrigeration unit to operate on different power platforms without requiring different harness configurations, achieving platform-agnostic compatibility.
Solution Approach 2:
The DC-DC converter within the power module dynamically adjusts voltage parameters based on the input power source characteristics. This parameter adaptation allows the system to accommodate different voltage levels and power delivery characteristics of battery versus fuel generator platforms, ensuring compatibility across different power sources through automated parameter adjustment.
3Reliability
If multiple separate power devices are installed in the transport refrigeration unit, then specific power requirements of different components can be met, but the overall system occupies large space and is difficult to maintain
Solution Approach 1:
By merging multiple power devices into a single integrated module, the patent reduces the number of separate components that need to be installed, wired, and maintained. The unified design simplifies the maintenance workflow while internal redundancy and modular architecture within the integrated unit preserve power supply reliability through failover capabilities and centralized monitoring.
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
The solution simplifies the power management system, reduces wiring complexity, enhances compatibility with various power sources, and improves operational convenience and safety by integrating functional modules within a compact design, applicable to both battery and fuel-powered vehicles.
Implementation Method 1
a DC buck module configured to step-down a DC at least provided by the battery to a low-voltage output DC for output
Implementation Method 2
a DC boost module configured to step-up a low-voltage input DC provided by the apparatus powered by the fuel to a high-voltage DC for output
Data Source
AI summary
An electrical power module and transport refrigeration system. The electrical power module is used for an apparatus powered by a battery or/and a fuel, has a working mode and includes: a DC buck module configured to step-down a DC at least provided by the battery to a low-voltage output DC for output, or/and a DC boost module configured to step-up a low-voltage input DC provided by the apparatus powered by the fuel to a high-voltage DC for output; and a control module connected to a transport refrigeration unit, and configured to, in the working mode, control the operation of the DC buck module or/and the DC boost module.