Motor-Winding Voltage Boost Charging for Higher-Voltage Batteries
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Solution Overview
Problem
Charging higher voltage batteries from a lower voltage power source requires additional power electronics, which can be complex and costly.
Innovation Solution
A power system utilizing a power electronics unit with half-bridges and switches that operate in inductor field building and collapsing phases to boost voltage, allowing charging with minimal modifications to existing hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If additional power electronics are used to charge higher voltage batteries from lower voltage power sources, then voltage boosting capability is achieved, but device complexity increases
Solution Approach 1:
The patent makes the existing motor-phase power electronics unit multi-functional by enabling it to perform both motor control and battery charging functions. The same power electronics switches and inductors are used for both driving the motor and boosting voltage for battery charging, eliminating the need for separate charging hardware and reducing overall system complexity.
Solution Approach 2:
The patent combines the motor control power electronics and battery charging power electronics into a single integrated unit. By merging these two functions into one system, the patent reduces the total number of components, simplifies the overall architecture, and lowers cost while maintaining voltage boosting capability for charging higher voltage batteries from lower voltage sources.
2Productivity
If additional power electronics are added for voltage boosting, then charging capability is improved, but cost increases
Solution Approach 1:
The existing motor-phase power electronics is made multi-functional to perform both motor control and battery charging. This eliminates the need to manufacture and install separate charging power electronics, thereby reducing manufacturing costs while maintaining full charging capability for higher voltage batteries.
Solution Approach 2:
By merging motor control and battery charging functions into a single power electronics unit, the patent reduces the total bill of materials and assembly requirements, directly lowering manufacturing costs while preserving enhanced charging capability.
3Device complexity
If motor windings are used as inductors for voltage boosting, then component count is reduced, but motor performance may be affected
Solution Approach 1:
The motor windings are made multi-functional by using them both for generating motor torque and for voltage boosting during battery charging. The same windings that drive the motor are utilized as inductors in the charging circuit, eliminating the need for separate inductor components while maintaining both motor performance and charging functionality through proper switch timing and control.
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
Efficiently charges higher voltage batteries from lower voltage sources with minimal hardware changes, compatible with various motor configurations, and reduces complexity and cost.
Implementation Method 1
The power electronics unit is operable to supply current from the power source to electric motor to establish inductor fields in the electric motor in the inductor field building phase
Implementation Method 2
The power electronics unit is operable to supply current from the electric motor to the battery upon a collapse of the established inductor fields in the electric motor in the inductor field collapse phase
Data Source
AI summary
An power system for an electric motor vehicle includes a power electronics unit connected to battery-side terminals, motor-side terminals and power source-side terminals. The power electronics unit including a plurality of half-bridges, each of the half-bridges including a pair of switches, each of the half-bridges connecting to a respective one of the motor-side terminals, the power electronics unit being operable to direct current from a power source through an electric motor to a battery to charge the battery by repeatedly operating the electric motor in an inductor field building phase, and then an inductor field collapse phase. The power electronics unit is operable to supply current from the power source to electric motor to establish inductor fields in the electric motor in the inductor field building phase. The power electronics unit is operable to supply current from the electric motor to the battery upon a collapse of the established inductor fields in the electric motor in the inductor field collapse phase. At least one of the half-bridges of the power electronics unit includes or is directly connected to the first power source-side terminal.