Integrated Motor Controller With Dual-Voltage Charging Circuits
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Solution Overview
Problem
Existing vehicle charging systems have limited versatility due to specific voltage requirements, resulting in poor user experience and reduced charging convenience.
Innovation Solution
An integrated motor controller with a dual charging circuit system, including a first charging circuit for high voltages and a second charging circuit with a boost module for low voltages, allowing for adaptable charging across various voltage ranges, along with additional components like capacitors and magnetic rings for enhanced safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single charging circuit with specific voltage requirement is used, then the charging system is simple, but the charging versatility is limited
Solution Approach 1:
The motor coil is designed to serve dual functions: as the motor winding during motor operation and as the inductor for the boost module during charging. This allows the charging system to handle multiple voltage levels (high voltage direct charging and low voltage boosted charging) using the same hardware components, thereby improving charging versatility without proportionally increasing device complexity
Solution Approach 2:
The patent merges the motor coil with the boost module inductor function. The motor coil is directly utilized as the energy storage inductor for voltage boosting during low-voltage charging, combining two previously separate functions into a single component, which reduces overall system complexity while enabling multi-voltage charging capability
2Adaptability or versatility
If a boost module is added for low voltage charging, then charging versatility improves, but device complexity increases
Solution Approach 1:
The boost module is merged with the existing motor controller structure. The motor coil serves as the inductor, and the IGBT module's bridge arm is utilized for voltage boosting. This integration approach allows low-voltage charging capability to be added without requiring completely separate boost circuitry, thereby limiting the increase in device complexity
Solution Approach 2:
The IGBT module is designed to perform multiple functions: motor control during driving and voltage boosting during charging. The bridge arm structure is utilized for both motor phase control and for creating the boosting action needed for low-voltage charging, enabling one component to serve multiple purposes and reducing overall system complexity
3Ease of operation
If dual charging circuits are implemented, then charging convenience improves, but control complexity increases
Solution Approach 1:
The control system incorporates voltage detection and comparison mechanisms that automatically determine whether the input voltage is high or low, and accordingly activate the appropriate charging circuit. This feedback-based automatic selection simplifies the control logic by using clear voltage thresholds to dictate circuit activation, reducing the complexity of manual control decisions
Solution Approach 2:
The charging system automatically selects and activates the appropriate charging circuit based on the detected input voltage level without requiring manual intervention. The control system self-determines whether to use direct high-voltage charging or boosted low-voltage charging, making the system self-service in terms of charging mode selection and thereby simplifying user operation
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
Enables high versatility and convenient charging across different charging voltages, ensuring safe and efficient battery charging while preventing damage from excessive voltages.
Implementation Method 1
The boost module includes a motor coil and an electrical control bridge arm. The motor coil is a coil of a driving motor. The motor coil is connected with the second charging circuit. The electrical control bridge arm is a bridge arm of an insulated gate bipolar transistor (IGBT) module of a motor controller.
Data Source
AI summary
An integrated motor controller includes a charging connector, a battery connector, a first charging circuit, and a second charging circuit. The first charging circuit is connected with the charging connector and the battery connector, and includes a first control switch. The first control switch is configured to control on/off of the first charging circuit. The second charging circuit is connected with the charging connector and the battery connector, and includes a boost module and a second control switch. The second control switch is configured to control on/off of the second charging circuit.