Mild Hybrid Voltage Conversion for Transport Climate Control
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Solution Overview
Problem
The existing transport climate control systems face challenges in managing energy sources due to incompatibility of voltages between battery packs and factory standard electric motors, leading to high costs for high-voltage battery packs and difficulties in finding suitable low-voltage motors for refrigeration units.
Innovation Solution
A mild hybrid system is introduced, comprising a prime mover, DC energy source, inverter, transformer, and AC to DC to DC buck converter, which converts DC voltage to suitable AC and then down to DC voltages matching the requirements of factory standard electric motors, thereby addressing voltage incompatibility issues cost-effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high-voltage battery packs are used to match the voltage requirements of factory standard electric motors, then voltage compatibility is achieved, but system cost increases significantly
Solution Approach 1:
The patent introduces an intermediary voltage conversion system comprising an inverter and transformer that converts DC voltage from low-voltage battery packs to AC voltage suitable for factory standard electric motors. This mediator approach allows the system to maintain voltage compatibility without requiring expensive high-voltage battery packs, thus resolving the contradiction between adaptability and manufacturing cost
Solution Approach 2:
The system dynamically changes voltage parameters through the inverter and transformer components, converting DC voltage from the battery pack to AC voltage at the appropriate level for the motor. This parameter transformation enables the use of lower-voltage, lower-cost battery packs while maintaining compatibility with standard motors
2Ease of manufacture
If low-voltage motors are used for refrigeration units, then system cost is reduced, but voltage incompatibility with battery packs arises
Solution Approach 1:
The inverter and transformer serve as intermediary devices that bridge the voltage gap between low-voltage battery packs and low-voltage motors. The inverter converts DC to AC, and the transformer adjusts the voltage level, enabling compatibility between components that would otherwise be incompatible, thus allowing cost-effective low-voltage motor usage
3Object-affected harmful factors
If emission control devices and auto start-stop systems are added to the vehicle power bay, then emissions are reduced, but space between the alternator and prime mover is reduced
Solution Approach 1:
The patent integrates multiple functions into the voltage conversion system, where the inverter and transformer not only perform voltage conversion but also serve as part of the overall power management architecture. This multi-functionality allows the system to accommodate emission control devices and start-stop systems within the constrained power bay space by optimizing the use of available components
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 mild hybrid system provides a cost-effective solution for managing energy sources in transport climate control systems by efficiently matching voltage requirements, reducing the need for high-voltage battery packs and enabling the use of readily available low-voltage motors, while ensuring safety and efficiency.
Implementation Method 1
an inverter connected to the DC energy source and configured to change the first DC voltage from the DC energy source to a first AC voltage
Implementation Method 2
a transformer connected to the inverter and configured to convert the first AC voltage to a second AC voltage
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Methods and systems for controlling energy source for a mild hybrid system (200) that powers a transport climate control system are provided. The mild hybrid system includes a DC energy source (240, 245, 250) configured to supply a first DC voltage to the transport climate control system. The system also includes an inverter (235) connected to the DC energy source (240, 245, 250) and configured to change the first DC voltage from the DC energy source to a first AC voltage. The system further includes a transformer ( 230) connected to the inverter (235) and configured to convert the first AC voltage to a second AC voltage. Also the system includes a motor (215) that drives a compressor (205). The motor (215) is driven by the second AC voltage, the second AC voltage is greater than the first AC voltage.