Inverter-Based Charging for 800V Electric Drive Systems
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Solution Overview
Problem
Electric vehicles with 800V batteries face challenges in backward compatibility when charging at 400V stations, requiring additional components and increasing weight and cost due to the need for extra voltage converters and circuit arrangements.
Innovation Solution
An electric drive system with two three-phase electric machines and inverters per drive axle allows for efficient charging at 400V or 500V stations by using the existing inverters for both driving and charging, eliminating the need for additional voltage converters and reducing weight and cost through torque vectoring and minimized electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional voltage converters and circuit arrangements are added to enable 800V vehicles to charge at 400V stations, then backward compatibility is improved, but device complexity and cost increase
Solution Approach 1:
The inverter is designed to perform multiple functions: it serves as both the power conversion device for the electric machine and as the voltage converter for charging operations. By integrating the charging function into the existing inverter structure, the system can handle both 800V and 400V charging scenarios without requiring separate dedicated voltage converters, thus improving backward compatibility while avoiding additional circuit complexity
Solution Approach 2:
The patent combines the charging circuit functionality with the existing inverter circuit. The inverter's switching elements and control structure are utilized for both motor drive operations and voltage conversion during charging. This merging of functions eliminates the need for separate voltage converter circuits, reducing overall system complexity while maintaining the ability to charge at different voltage levels
2Adaptability or versatility
If additional voltage converters and circuit arrangements are added to enable 800V vehicles to charge at 400V stations, then backward compatibility is improved, but vehicle weight increases
Solution Approach 1:
The inverter is designed to perform multiple functions: it serves as both the power conversion device for the electric machine and as the voltage converter for charging operations. By integrating the charging function into the existing inverter structure, the system can handle both 800V and 400V charging scenarios without requiring separate dedicated voltage converters, thus improving backward compatibility while avoiding additional circuit complexity
Solution Approach 2:
The patent combines the charging circuit functionality with the existing inverter circuit. The inverter's switching elements and control structure are utilized for both motor drive operations and voltage conversion during charging. This merging of functions eliminates the need for separate voltage converter circuits, reducing overall system complexity while maintaining the ability to charge at different voltage levels
3Adaptability or versatility
If additional voltage converters and circuit arrangements are added to enable 800V vehicles to charge at 400V stations, then backward compatibility is improved, but manufacturing cost increases
Solution Approach 1:
The inverter is designed to perform multiple functions: it serves as both the power conversion device for the electric machine and as the voltage converter for charging operations. By integrating the charging function into the existing inverter structure, the system can handle both 800V and 400V charging scenarios without requiring separate dedicated voltage converters, thus improving backward compatibility while avoiding additional circuit complexity
Solution Approach 2:
The patent combines the charging circuit functionality with the existing inverter circuit. The inverter's switching elements and control structure are utilized for both motor drive operations and voltage conversion during charging. This merging of functions eliminates the need for separate voltage converter circuits, reducing overall system complexity while maintaining the ability to charge at different voltage levels
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
Enables efficient and cost-effective charging of 800V vehicles at lower voltage stations, reducing the need for additional components and minimizing electromagnetic interference, thereby enhancing backward compatibility and reducing vehicle weight and cost.
Implementation Method 1
in accordance with the first and/or second inverter a charging voltage of the onboard charging terminal can be converted into a supply voltage for charging the electrical energy store
Implementation Method 2
a first three-phase electric machine and a second three-phase electric machine for driving at least one drive axle of the vehicle
Data Source
AI summary
An electric drive system for a vehicle includes first and second three-phase electric machines driving a vehicle axle and an electrical energy store electrically supplying the first and second three-phase electric machines during a driving operation of the vehicle. A first and second inverter of the first and second three-phase electric machines, respectively, are each coupled to the electrical energy store. The system also includes an onboard charging terminal for electrically coupling the electrical energy store to a charging unit external to the vehicle. According to the first and/or second inverter, a charging voltage of the onboard charging terminal is converted into a supply voltage for charging the electrical energy store.