Motor Stator Winding Reconfiguration for Converter-Free Battery Charging
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Solution Overview
Problem
Existing vehicle charging systems face inefficiencies when using DC to DC converters to boost battery voltage, as they are costly, add weight, and occupy space, especially when the charger's voltage is lower than the battery's voltage.
Innovation Solution
The system employs stator windings of an electric motor to boost the output voltage of an AC or DC power source to charge the battery, utilizing switches to galvanically isolate stator winding portions and reconfigure them for voltage boosting, eliminating the need for separate DC to DC converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If DC to DC converters are used to boost battery voltage, then the battery can be charged when charger voltage is lower than battery voltage, but the system becomes more complex, costly, and heavier
Solution Approach 1:
The electric motor's stator windings are designed to serve dual purposes: motor operation during vehicle propulsion and voltage boosting during battery charging. By reconfiguring the existing motor windings through switch control, the system eliminates the need for separate DC to DC converters, reducing complexity while maintaining charging capability across different voltage conditions
Solution Approach 2:
The patent combines the voltage boosting function with the existing electric motor structure by utilizing its stator windings. The motor housing and windings serve both their original propulsion function and the new charging function, merging multiple system functions into a single integrated component that reduces overall system complexity
2Adaptability or versatility
If DC to DC converters are used to boost battery voltage, then the battery can be charged when charger voltage is lower than battery voltage, but the vehicle weight increases
Solution Approach 1:
The electric motor's stator windings are designed to serve dual purposes: motor operation during vehicle propulsion and voltage boosting during battery charging. By reconfiguring the existing motor windings through switch control, the system eliminates the need for separate DC to DC converters, reducing complexity while maintaining charging capability across different voltage conditions
Solution Approach 2:
The patent combines the voltage boosting function with the existing electric motor structure by utilizing its stator windings. The motor housing and windings serve both their original propulsion function and the new charging function, merging multiple system functions into a single integrated component that reduces overall system complexity
3Adaptability or versatility
If DC to DC converters are used to boost battery voltage, then the battery can be charged when charger voltage is lower than battery voltage, but the cost increases
Solution Approach 1:
The electric motor's stator windings are designed to serve dual purposes: motor operation during vehicle propulsion and voltage boosting during battery charging. By reconfiguring the existing motor windings through switch control, the system eliminates the need for separate DC to DC converters, reducing complexity while maintaining charging capability across different voltage conditions
Solution Approach 2:
The patent combines the voltage boosting function with the existing electric motor structure by utilizing its stator windings. The motor housing and windings serve both their original propulsion function and the new charging function, merging multiple system functions into a single integrated component that reduces overall system complexity
4Productivity
If standard charging systems are used, then the battery charges at standard rates, but the charging speed is limited and range per hour is lower
Solution Approach 1:
The system dynamically reconfigures the stator windings based on operating conditions, switching between different connection patterns (series, parallel, or combinations) to optimize charging power. This dynamic reconfiguration allows the system to adapt to different charging requirements and achieve higher power transfer rates compared to static charging systems
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 enables fast and efficient battery charging without the need for additional converters, reducing costs and vehicle weight, while providing galvanic isolation and allowing for higher charging rates, such as over 50 kW/h and 180 miles of range per hour.
Implementation Method 1
Battery charging systems and methods via electric machine... charge the battery with power from the AC power source using the first, second, and third stator windings of the electric machine
Data Source
AI summary
An electric machine includes: a first stator winding including first and second stator winding portions; a second stator winding including third and fourth stator winding portions; a third stator winding including fifth and sixth stator winding portions, where inputs of the stator windings are configured to be connected to phases, respectively, of an inverter; and switches connected between the stator winding portions and outputs of a power source.