Modular Brake Actuator With Variable Resistance for Energy Fluctuation Control
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Solution Overview
Problem
Existing modular brake actuators face challenges in efficiently managing energy fluctuations and optimizing submodule capacitor design due to fixed resistance values, leading to inefficiencies and increased costs.
Innovation Solution
A modular braking unit with a series circuit comprising submodules and a braking resistor, where the resistance value can be dynamically controlled to adapt to power conversion needs, using switches and partial resistors to minimize energy fluctuations and optimize submodule capacitor design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a fixed resistance value is used in the braking unit, then the design is simple, but energy fluctuations in submodule capacitors increase and power conversion efficiency decreases
Solution Approach 1:
The braking unit employs a variable resistance value that can be dynamically adjusted based on operating conditions. The control device modifies the resistance of the braking resistor in real-time to optimize energy dissipation and minimize fluctuations in submodule capacitor energies, thereby resolving the contradiction between energy efficiency and device simplicity.
Solution Approach 2:
The invention changes the resistance parameter of the braking resistor from a fixed value to a variable value that can be adapted to different operating conditions. By adjusting the resistance parameter dynamically, the system optimizes power conversion efficiency and reduces energy fluctuations without requiring complete redesign of the braking unit architecture.
2Power
If a low resistance value is used to convert high power into heat, then power conversion capability increases, but energy fluctuations in submodules increase
Solution Approach 1:
The braking unit dynamically adjusts the resistance value based on the instantaneous power level and operating conditions. During high-power braking events, the resistance is lowered to maximize power conversion capability. During normal or low-power operation, the resistance is increased to minimize energy fluctuations in the submodules, thus resolving the contradiction between power capability and energy stability.
3Power
If the braking resistor always converts power into heat, then power dissipation is maximized, but losses during idle operation increase
Solution Approach 1:
The control device dynamically switches the braking resistor between active and inactive states based on operational requirements. During braking operations, the resistor is activated to dissipate power as heat. During idle operation, the resistor is deactivated or bypassed to minimize energy losses, thereby resolving the contradiction between maximizing power dissipation and minimizing idle losses.
4Loss of energy
If submodule capacitor capacitance is increased to reduce energy fluctuations, then energy stability improves, but manufacturing costs and device size increase
Solution Approach 1:
Instead of increasing capacitor capacitance to reduce energy fluctuations, the invention changes the resistance parameter of the braking resistor to dynamically compensate for energy variations. This approach achieves energy stabilization without requiring larger or more expensive capacitors, thus resolving the contradiction between energy stability and manufacturing cost.
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
This approach reduces energy fluctuations, allows for more efficient power conversion, lowers manufacturing costs, and enhances the operational efficiency of the brake actuator, particularly in idle modes, while maintaining stability in power grids and electrical systems.
Implementation Method 1
the resistance value of the braking resistor can be changed by a control device... suitable for converting electrical energy generated by an electrical machine during braking into heat
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a modular braking unit (1), wherein the modular braking unit (1) comprises at least one submodule (2) and a braking resistor (3), wherein the at least one submodule (2) and the braking resistor (3) are arranged in a series circuit (14). To improve the modular braking unit, it is proposed that the resistance value (RB) of the braking resistor (3) be variable by a control device (4). Furthermore, the invention relates to a modular drive unit (10) comprising a modular multilevel power converter (11) and such a modular braking unit (1), wherein the multilevel power converter (11) is connected to the modular braking unit (1) on the DC voltage side.The invention further relates to a method for operating such a modular brake actuator (1) or such a modular drive unit (10), wherein the control device (4) changes the resistance value (RB) of the modular brake actuator (1) as a function of the power (Pss) to be converted into heat.