Inverter Topology Sharing IGBTs and Diodes
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Solution Overview
Problem
Existing inverter topologies for electric motors in machines require a large number of expensive and prone-to-failure components, such as IGBTs and diodes, which increases costs and reduces reliability.
Innovation Solution
The inverter topology shares common insulated-gate bipolar transistors and diodes among multiple phase modules, reducing the overall quantity of switches and diodes required, thereby improving manufacturability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inverter topology with separate IGBTs and diodes for each phase is used, then the inverter can provide sufficient power switching capability, but the quantity of components increases (2n components), leading to higher cost and reduced reliability
Solution Approach 1:
The patent merges the switching functions by sharing a common IGBT among multiple phase legs and combines diode functions by using shared diodes across phases. This merging reduces the total component count from 2n to n+1 components while maintaining the necessary power switching capability for all phases.
Solution Approach 2:
The common IGBT serves multiple functions by providing switching capability for multiple phase legs simultaneously. The shared diodes provide multiple functions by handling reverse recovery and freewheeling currents for different phases, making each component universally applicable across multiple phases rather than dedicated to a single phase.
2Power
If more IGBTs and diodes are used in the inverter topology, then the power switching capability is sufficient, but the cost increases and the components are more prone to failure
Solution Approach 1:
The patent merges power switching functions across multiple phases by using a single common IGBT that can switch currents for multiple phase legs. This consolidation reduces the total number of expensive IGBTs required while maintaining sufficient power handling capability through proper current sharing and switching coordination.
Solution Approach 2:
The diodes are designed to serve multiple phases simultaneously, providing universal functionality for reverse recovery and freewheeling operations across different phase legs. This multi-functionality reduces the total diode count and associated costs while maintaining necessary power protection capabilities.
3Ease of manufacture
If a reduced quantity of components is used in the inverter, then cost is reduced and reliability is improved, but the inverter topology becomes more complex to design and implement
Solution Approach 1:
The inverter is segmented into modular phase legs that share common components. This segmentation allows for systematic design where each phase leg follows a similar structure, making the reduced component topology more manageable and easier to design systematically rather than creating a completely new complex architecture.
Data Source
AI summary
An electrical inverter may include a plurality of phase modules to provide a plurality of phase outputs. Two or more of the plurality of phase modules may share a common insulated-gate bipolar transistor.