Integrated Inverter Power Module With Winding Changeover Switching

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Solution Overview

Problem

Existing motor driving technologies face challenges in maximizing inverter-motor power conversion efficiency, leading to degraded fuel efficiency and limited motor torque, especially when trying to cover both low-output and high-output ranges with a single motor.

Innovation Solution

An inverter power module integrated with a switch that is switched according to a motor driving mode, incorporating a positive terminal, negative terminal, output terminal, top switch, bottom switch, and changeover switch, allowing for closed-end and open-end winding modes to optimize motor performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If the motor winding number is increased to increase the motor maximum torque, then the maximum motor torque is improved, but the range having a high voltage usage ratio becomes far from the low-torque area, degrading the fuel efficiency

Engineering Contradiction:
Improvemotor maximum torqueVSAvoidfuel efficiency
Core Design Contradiction:
ForceVSUse of energy by moving object

Solution Approach 1:

The patent implements dynamic switching between two inverter configurations (first inverter with standard switches and second inverter with changeover switches) based on the motor operating conditions. The controller selects the appropriate inverter configuration according to the required torque level, enabling the system to adapt its voltage usage ratio dynamically. This resolves the contradiction by allowing high torque output when needed while maintaining high fuel efficiency in low-torque operating conditions through the changeover switch mechanism that optimizes voltage utilization.

Inventive Principle:
Principle #15Dynamics

2Use of energy by moving object

If a major driving point is designed to be included in the range having a high voltage usage ratio from the viewpoint of fuel efficiency, then the fuel efficiency is improved, but the maximum motor torque is limited, degrading the accelerating/starting performance of the vehicle

Engineering Contradiction:
Improvefuel efficiencyVSAvoidmaximum motor torque
Core Design Contradiction:
Use of energy by moving objectVSPower

Solution Approach 1:

The patent creates a universal motor driving system that can perform multiple functions through a single integrated design. The dual inverter configuration with changeover switches enables the system to provide both high fuel efficiency (through optimized voltage usage ratio in normal mode) and high maximum torque (through alternative connection paths in changeover mode). This multi-functional design resolves the contradiction by making the system capable of delivering both efficiency and power performance depending on operating conditions.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If two inserters and a mode-switching switch are used to drive a single motor in two different modes, then both low-output and high-output ranges are covered, but the area and cost required for the motor driving apparatus increases

Engineering Contradiction:
Improvemotor driving range coverageVSAvoidarea and cost
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the functionality of two separate inverters into a single integrated power module. The first inverter and second inverter are combined in one physical module, sharing common components such as the DC power connection and motor connection. The changeover switches are integrated within the same module structure, allowing mode switching without requiring separate physical inverters. This merging approach resolves the contradiction by providing dual-mode operation capability while minimizing the increase in area and cost compared to completely separate systems.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12470163B2Power module
Publication Date: 2025.11.11 HYUNDAI MOTOR CO LTD
  • US12470163B2 patent drawing
  • US12470163B2 patent drawing
  • US12470163B2 patent drawing

AI summary

A power module may include: a positive terminal connected to a positive pole of a battery; a negative terminal connected to a negative pole of the battery; an output terminal connected to a winding among multiple windings included in a motor; a changeover terminal connected to a neutral point regarding the multiple windings; a top switch connected between the positive terminal and the output terminal; a bottom switch connected between the negative terminal and the output terminal; and a changeover switch connected to the changeover terminal and configured to form a common node with at least one of the top switch or the bottom switch.