Actuator Motor Drive Voltage Limiting for Wide-Input HVDC
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Solution Overview
Problem
High-voltage direct current (DC) motor drive systems face constraints due to increased creepage and clearance requirements for components beyond 500V, making commercial-off-the-shelf options impractical and leading to increased costs and lead times for customized designs.
Innovation Solution
An intelligent architecture system that regulates voltage by operating in various modes, including inrush current limiting, DC link voltage limiting, and input voltage bypass modes, using a voltage limiter, logic selector, PWM generator, and sensing units to control the output voltage based on input voltage levels, allowing the use of standard COTS components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage direct current (exceeding 500V) is used in motor drive systems, then power transmission capability is improved, but creepage and clearance requirements increase exponentially, making component selection impractical
Solution Approach 1:
The patent divides the high-voltage power transmission path into multiple lower-voltage stages using series-connected motor drive units. Each unit operates at a manageable voltage level (e.g., 400V DC link) while collectively achieving the desired high-voltage power transmission capability. This segmentation allows standard COTS components to be used in each stage without requiring excessive creepage and clearance distances.
Solution Approach 2:
The patent introduces an intelligent architecture with voltage regulation circuitry as an intermediary between the DC link and motor phases. This intermediary actively manages voltage distribution and isolation, enabling safe operation with standard component spacing while maintaining high-voltage power transmission capability through coordinated control of multiple motor drive units.
2Adaptability or versatility
If customized design solutions are formulated to meet high-voltage requirements, then component compatibility is improved, but overall costs and lead times increase
Solution Approach 1:
The patent designs motor drive units with universal interfaces and standardized voltage levels (e.g., 400V DC link) that can be mass-produced as COTS components. The intelligent architecture provides multi-functionality by adapting these standard units to different high-voltage applications through coordinated control, eliminating the need for customized hardware designs while maintaining component compatibility across various power levels.
Solution Approach 2:
The patent establishes preliminary design standards and voltage level specifications (e.g., 400V DC link, specific creepage/clearance requirements) that enable manufacturers to pre-produce compatible COTS components. This preliminary standardization allows designers to select from available off-the-shelf parts rather than developing customized solutions, significantly reducing lead times while ensuring proper high-voltage compatibility.
3Ease of manufacture
If standard COTS components are used, then manufacturing cost is reduced, but voltage stress on components increases beyond safe operating limits
Solution Approach 1:
The patent employs dynamic voltage management through intelligent control architecture that actively adjusts voltage distribution across motor drive units in real-time. This dynamic approach ensures that standard COTS components never experience excessive voltage stress by coordinating the operation of series-connected units and providing over-voltage protection, while still enabling high-voltage power transmission capability when needed.
Solution Approach 2:
The patent implements feedback control mechanisms with voltage sensing and regulation circuitry that continuously monitor component voltage levels and adjust operation accordingly. This feedback system prevents standard COTS components from experiencing dangerous voltage stress by detecting and correcting over-voltage conditions, while maintaining the ability to operate at high voltage levels through coordinated control of multiple series-connected motor drive units.
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 solution reduces voltage stress on components, enables the use of standard components, and decreases PCB size and thickness, resulting in lower costs, reduced lead times, and increased reliability, while allowing for higher voltage operations.
Implementation Method 1
a voltage limiter disposed along the main line
Implementation Method 2
a pulse width modulation (PWM) generator to drive an operation of the voltage limiter in accordance with a signal from the logic selector
Data Source
AI summary
An intelligent architecture system is provided. The intelligent architecture system includes an input line, an output line and an intelligent architecture operably interposed between the input line and the output line. The intelligent architecture is configured to control a voltage of the output line in accordance with a voltage of the input line.