Electric Assembly Using Motor Windings for Battery Self-Heating
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Solution Overview
Problem
Existing electric assemblies for vehicles face inefficiencies in charging and discharging battery packs at low temperatures, leading to suboptimal energy utilization and requiring additional components like PTC heating members, which increase costs and complexity.
Innovation Solution
The electric assembly incorporates self-heating of battery packs, reusing the three-phase winding of the motor and bridge arms of the electric control module in the self-heating circuits, thereby reducing component count, volume, and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a PTC heating member is added to heat the battery pack, then the battery pack can be heated in low-temperature conditions, but the number of components, cost, and volume of the electric assembly increase
Solution Approach 1:
The motor's three-phase winding is designed to serve dual functions: motor operation and battery pack heating. By controlling current flow through the winding during low-temperature conditions, the system achieves heating capability without requiring a separate heating device, thus reducing component count while maintaining temperature control functionality
Solution Approach 2:
The heating function is merged with the motor structure by utilizing the motor's three-phase winding as the heating element. This integration eliminates the need for a separate PTC heating member, combining two functions (motor operation and heating) into a single component structure, thereby reducing overall device complexity and component quantity
2Temperature
If a PTC heating member is added to heat the battery pack, then the battery pack can be heated in low-temperature conditions, but the cost and volume of the electric assembly increase
Solution Approach 1:
The motor's three-phase winding serves dual purposes as both a motor component and a heating element. This multi-functionality eliminates the need for additional heating components, thereby reducing the overall volume of the electric assembly while maintaining the capability to heat the battery pack in low-temperature conditions
Solution Approach 2:
The heating function is integrated into the motor structure by using the three-phase winding for both motor operation and heating. This merging of functions removes the need for separate heating components, directly reducing the volume occupied by heating elements in the electric assembly
3Temperature
If a PTC heating member is added to heat the battery pack, then the battery pack can be heated in low-temperature conditions, but the cost of the electric assembly increases
Solution Approach 1:
The motor's three-phase winding is designed to perform both motor function and heating function. By utilizing existing components for dual purposes, the system eliminates the need to manufacture and install separate heating elements, thereby reducing manufacturing costs while maintaining temperature control capability in low-temperature conditions
Solution Approach 2:
The heating function is combined with the motor structure through the three-phase winding. This integration eliminates the need for separate heating components, reducing the bill of materials and assembly costs, thereby improving ease of manufacture and reducing overall electric assembly cost
4Device complexity
If the three-phase winding and bridge arms are reused in self-heating circuits, then the number of components is reduced, but the system must handle multiple functions simultaneously
Solution Approach 1:
The three-phase winding and bridge arms are designed to operate in multiple modes: motor operation mode and self-heating mode. The control system switches between these modes based on operational requirements, allowing the same components to serve different functions without compromising system adaptability or performance in either mode
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 enhances energy efficiency by enabling self-heating of battery packs, reduces the number of components and costs, and maintains the battery packs in an efficient operating state, even in low-temperature conditions.
Implementation Method 1
self-heating of battery packs can be implemented, and a three-phase winding of a motor and bridge arms of an electric control module are also reused in self-heating circuits of the battery packs
Implementation Method 2
The electric control module includes an IGBT module. The IGBT module includes a three-phase bridge arm
Data Source
AI summary
An electric assembly includes a box body, an N-line connecting assembly, a motor, an electric control module, and a direct-current connector. The box body comprises an electric control cavity. One end of the N-line connecting assembly is suitable for being connected between two battery packs connected in series. The motor comprises a three-phase winding, one end of the three-phase winding is a junction end, which is connected to the other end of the N-line connecting assembly. The electric control module comprises an IGBT module having a three-phase bridge arm, and the other end of the three-phase winding is connected to a middle point of the three-phase bridge arm. A positive electrode of the direct-current connector is connected to the junction end, and a negative electrode of the direct-current connector is connected to the IGBT module and is suitable for being connected to negative electrodes of the battery packs.