Parallel Power Module Motor Controller for Low-Loss Heating
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Solution Overview
Problem
Existing motor control systems suffer from low heating rates, loud motor noise, and large heat losses due to significant eddy current losses in the control circuit.
Innovation Solution
A motor controller design incorporating parallel-connected power modules, a voltage stabilization capacitor, and a switch mechanism to adapt to different heating scenarios, along with a coolant system for improved heat dissipation and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If self-heating of battery is implemented using conventional motor control methods, then heating function is achieved, but large eddy current loss occurs causing heat loss and low heating rate
Solution Approach 1:
The patent segments the power module into multiple independent units (first power modules and second power module) with separate control circuits. This segmentation allows independent optimization of each module's operation, enabling selective activation and control to minimize eddy current losses while maintaining heating effectiveness. The segmented architecture permits parallel operation of multiple modules to achieve higher heating rates without proportionally increasing losses.
Solution Approach 2:
The patent implements dynamic control through separate control circuits for different power modules, allowing real-time adjustment of module activation and power distribution. The switch mechanism enables dynamic reconfiguration of the heating circuit topology, optimizing the balance between heating rate and eddy current losses based on operating conditions. This dynamic adaptability resolves the contradiction by allowing the system to operate at high heating rates when necessary while minimizing losses during normal operation.
2Object-affected harmful factors
If conventional heating methods are used, then heating function is provided, but motor noise increases
Solution Approach 1:
The patent divides the heating power into multiple segments through separate power modules (first power modules connected in parallel and second power module), each controlled independently. This segmentation allows the heating power to be distributed across multiple modules operating at lower individual power levels, reducing motor noise while maintaining total heating power. The segmented approach enables selective activation of modules to optimize the noise-power balance.
Solution Approach 2:
The patent combines multiple power modules with separate control circuits to achieve the required total heating power. By merging the output of multiple low-noise modules, the system achieves high heating power without the noise associated with a single high-power module. The parallel connection of first power modules with the second power module allows their combined output to deliver high heating power while each module operates in a lower-noise regime.
3Loss of energy
If parallel-connected power modules are used to reduce eddy current loss, then heating efficiency improves, but device complexity increases
Solution Approach 1:
The patent segments the power system into modular units with standardized interfaces and control circuits. This segmentation, while increasing component count, reduces overall system complexity through modularity, allowing for standardized design, easier manufacturing, and simplified maintenance. The segmented architecture enables the parallel connection of power modules to reduce eddy current losses while keeping each module's internal complexity manageable and standardized.
Solution Approach 2:
The patent designs power modules with universal, multi-functional capabilities that can operate in different configurations (parallel or series) and serve multiple functions (heating, power conversion, etc.). This universality reduces the need for specialized components for each configuration, thereby reducing overall device complexity despite the parallel module architecture. The standardized multi-functional modules can be reused across different applications and configurations.
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 effectively reduces eddy current losses, enhances heating efficiency, and minimizes motor noise, while providing adaptable heating solutions for various applications.
Implementation Method 1
a first capacitor connected in parallel to the second power module, where the plurality of first power modules and the second power module are configured to perform temperature regulation
Implementation Method 2
the plurality of first power modules and the second power module are configured to perform temperature regulation on an object connected to the first group of connecting interfaces and the second group of connecting interfaces
Data Source
AI summary
A motor controller includes: a plurality of first power modules, a second power module, a first group of connecting interfaces, a second group of connecting interfaces, and a first capacitor, where the plurality of first power modules are connected in parallel to each other, and the plurality of first power modules are configured to connect to the first group of connecting interfaces; the second power module is configured to connect to the second group of connecting interfaces; and the first capacitor is connected in parallel to the second power module, where the plurality of first power modules and the second power module are configured to perform temperature regulation on an object connected to the first group of connecting interfaces and the second group of connecting interfaces.