Integrated Inverter Power Module Assembly for Reconfigurable Motor Windings

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Solution Overview

Problem

Inverter circuits for high voltage applications, such as electric vehicles, face challenges with increased heat generation, complex control, and excessive high voltage cabling due to various winding configurations of motors, which complicate fault safety and cooling.

Innovation Solution

A highly integrated power switch module topology with dual inverters housed together, utilizing SiC MOSFETs and a changeover switch to simplify internal assembly, reduce volume, and enhance thermal management, allowing efficient reconfiguration between Delta and Wye winding configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additional high voltage cabling and complicated control are used to support various winding configurations, then motor torque and power output manipulation capability is improved, but device complexity and heat generation increase

Engineering Contradiction:

Improvewinding configuration capabilityVSAvoidcabling and control complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple inverters into a single integrated power module assembly, combining dual three-phase inverters with shared DC rails, common cooling structures, and integrated control electronics. This consolidation maintains the capability to support various winding configurations (Delta, Wye, Open End) while reducing overall system complexity by eliminating redundant cabling and control components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power module assembly is designed with universal functionality to support multiple motor winding configurations through a single standardized interface. The dual inverter architecture with reconfigurable power distribution enables the same hardware to drive motors in Delta, Wye, or Open End configurations, eliminating the need for separate specialized systems for each winding type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If additional high voltage cabling is used to support various winding configurations, then motor torque and power output manipulation capability is improved, but heat generation increases

Engineering Contradiction:

Improvewinding configuration capabilityVSAvoidheat generation

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent addresses heat generation by integrating advanced thermal management systems that convert the harmful thermal byproduct into manageable energy flow. The common cooling structure with optimized thermal paths and heat dissipation mechanisms efficiently channels heat away from power electronics, transforming the heat generation issue into a controlled thermal management scenario.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Adaptability or versatility

If complicated control systems are used to support various winding configurations, then motor torque and power output manipulation capability is improved, but fault safety complexity increases

Engineering Contradiction:

Improvewinding configuration capabilityVSAvoidfault safety logic complexity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements comprehensive feedback systems with sensors and control algorithms that continuously monitor system state and automatically adjust control parameters. This feedback mechanism simplifies fault safety logic by providing real-time system state information, enabling automatic detection and response to configuration changes or fault conditions without complex manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control system incorporates self-diagnostic and self-adjustment capabilities that automatically manage winding configuration transitions and fault detection. The system performs self-verification of connection states and automatically adapts control strategies based on detected configurations, reducing the burden on external fault safety logic and improving overall reliability.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250286492A1Systems for power module assembly for inverter

Publication Date: 2025.09.11 BORGWARNER US TECHNOLOGIES LLC

AI summary

Disclosed solutions relate to electrical inverters. In an example, an inverter to convert DC power from a voltage source to AC power to drive a motor is disclosed. The inverter includes a first power module. The first power module includes first phase switches, second phase switches and positive DC power tabs connected to a positive DC rail to provide positive DC power to the first phase switches and the second phase switches. The inverter further includes negative DC power tabs connected to a negative DC rail to provide negative DC power to the first phase switches and the second phase switches. The inverter further includes first phase AC power tabs to receive AC power from the first phase switches. The inverter further includes second phase AC power tabs to receive AC power from the second phase switches.