Modular Brake Actuator Branch Control for Stable Heat Dissipation
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Solution Overview
Problem
Existing modular braking units lack efficient methods for converting electrical energy into heat while maintaining stable operation over extended periods, particularly in continuous operation.
Innovation Solution
A modular braking unit design featuring at least two branches, each with a series circuit of submodules and a braking resistor, arranged in parallel. This design allows for the generation of an alternating voltage component without DC components, enabling precise control of power conversion into heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single brake actuator branch is used, then the device complexity is reduced, but the ability to convert electrical energy into heat efficiently and stably is insufficient
Solution Approach 1:
The brake actuator is divided into multiple parallel branches, each capable of independently generating alternating voltage components with different phase shifts. This segmentation allows the system to distribute energy conversion across multiple paths, improving overall efficiency while maintaining manageable complexity through modular design
Solution Approach 2:
Each brake actuator branch generates an alternating voltage component that is periodic in nature, with phase shifts between branches. This periodic action enables continuous energy conversion into heat through the braking resistors, ensuring stable operation over extended periods by continuously cycling energy dissipation
2Power
If DC components are present in the voltage generated by brake actuator branches, then the power conversion capability is enhanced, but the stability of operation over extended periods deteriorates
Solution Approach 1:
The invention extracts and eliminates the DC component from the voltage generated by each brake actuator branch, retaining only the alternating voltage components. This extraction ensures that no net DC current flows through the braking resistors, preventing drift and maintaining stable operation over extended periods while still enabling effective power conversion through the alternating components
Solution Approach 2:
The invention changes the voltage parameter from including DC components to consisting solely of alternating components with controlled phase shifts. This parameter change transforms the operating characteristics to achieve both adequate power conversion capability and enhanced long-term stability by eliminating DC-induced drift
3Loss of energy
If the brake actuator is designed for high power conversion, then the energy dissipation capability is improved, but the adaptability to different intermediate circuit voltages deteriorates
Solution Approach 1:
The brake actuator employs dynamically controllable alternating voltage components with adjustable phase shifts between branches. This dynamic control allows the system to adapt to different intermediate circuit voltages while maintaining high energy dissipation capability, as the phase shifts and voltage amplitudes can be adjusted to match various operating conditions
Solution Approach 2:
The multi-branch design with controllable alternating voltage components provides universal adaptability to different intermediate circuit voltages. Each branch can be configured to contribute appropriately to the total energy dissipation, making the brake actuator versatile across different voltage levels and application scenarios while maintaining high power conversion efficiency
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 solution enables precise control and regulation of power conversion into heat, ensuring stable operation even over longer periods. It allows for adaptation to any intermediate circuit voltage and can operate with passive converters, enhancing reliability and adaptability.
Implementation Method 1
The resistance of a braking actuator arrangement is often also referred to as a braking resistor, as it is suitable for converting electrical energy from an electrical machine, which is generated as a result of a braking process, into heat
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method for operating a modular braking actuator (1), wherein the modular braking actuator (1) has at least two braking actuator branches (15), wherein the braking actuator branches (15) each have at least one submodule (2) and a braking resistor (3), wherein the braking actuator branches (15) are arranged in a parallel circuit, wherein at least two of the braking actuator branches (15) generate a voltage (uBR) with an alternating component (uBR,aDC) by means of the corresponding at least one submodule (2), wherein the alternating components (uBR,aDC) of the individual braking actuator branches (15) have a phase shift of 2πn with respect to one another, wherein n corresponds to the number of voltage-generating braking actuator branches (15), wherein the amplitude of all alternating components (uBR,aDC) is the same and is dimensioned such that the electrical energy absorbed on average over time by the modular braking actuator (1) is converted into heat in the braking resistor (3).The invention further relates to a control device (10) configured to carry out such a method. The invention further relates to a modular brake actuator (1) having such a control device, as well as to a modular drive unit (20) comprising a modular multilevel power converter (21) and such a modular brake actuator (1).