Motor Winding DC Charging for Modular EV Battery Inverters

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Solution Overview

Problem

Existing eco-friendly vehicle driving systems face challenges in rapid charging using general chargers, especially when multiple battery modules are combined to drive the motor, leading to inefficiencies and increased costs due to the need for high-voltage components and complex power conversion systems.

Innovation Solution

The vehicle incorporates a plurality of single-phase battery module systems connected to motor windings, each including a battery and a power conversion module with an inverter that converts DC voltage to AC voltage. During DC charging, the inverter transfers DC power from the charger to the battery through the motor windings, allowing for rapid charging using a general charger.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple battery modules are combined to drive the motor, then the vehicle can achieve required power output, but rapid charging using a general charger becomes difficult and requires high-voltage components

Engineering Contradiction:

Improvemotor power outputVSAvoidcompatibility with general charger

Core Design Contradiction:

PowerVSAdaptability or versatility

Solution Approach 1:

The battery system is divided into multiple single-phase battery module systems, each connected to motor windings. During DC charging, the inverter transfers DC power from the charger to the battery through the motor windings, enabling general chargers to be used without requiring high-voltage components. This segmentation allows the system to maintain compatibility with standard charging infrastructure while achieving the required power output through combined operation of multiple modules.

Inventive Principle:

Principle #1Segmentation

2Power

If multiple battery modules are combined, then the vehicle achieves required power, but the power conversion system becomes complex and costly

Engineering Contradiction:

Improvemotor power outputVSAvoidpower conversion system complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The inverter is designed to perform multiple functions: it converts DC voltage to AC voltage for motor operation and also serves as a power transfer pathway during DC charging. By making the inverter multi-functional, the system avoids adding separate charging-specific components, thereby reducing overall system complexity and cost while maintaining the capability to handle multiple battery modules for required power output.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If multiple battery modules are combined, then the vehicle achieves required power, but production costs increase due to high-voltage components

Engineering Contradiction:

Improvemotor power outputVSAvoidproduction cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

Instead of charging the battery directly through high-voltage pathways as in conventional systems, the patent inverts the charging pathway by routing DC charging power through the motor windings via the inverter. This inversion eliminates the need for high-voltage charging components, significantly reducing production costs while still enabling the system to combine multiple battery modules to achieve the required power output.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enables rapid charging of the vehicle using a general charger, even when multiple battery modules are combined, reducing the need for high-voltage components and complex power conversion systems, thereby improving efficiency and lowering production costs.

Implementation Method 1

an inverter configured to convert direct current voltage stored in the battery into alternating current (AC) voltage and to control a motor

Methodology Applied

Scientific EffectPower conversion:

Implementation Method 2

the inverter operates to transfer direct current (DC) power supply provided from a charger to the battery through the plurality of motor windings during DC charging

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250050764A1Vehicle and charging control method of vehicle

Publication Date: 2025.02.13 HYUNDAI MOTOR CO LTD

AI summary

A vehicle includes a motor comprising a plurality of motor windings, and a plurality of single-phase battery module systems connected to the plurality of motor windings, respectively, and including plurality of battery modules, wherein each of the plurality of battery modules includes a battery and a power conversion module, and the power conversion module includes an inverter configured to convert direct current voltage stored in the battery into alternating current (AC) voltage and to control a motor, wherein the inverter operates to transfer direct current (DC) power supply provided from a charger to the battery through the plurality of motor windings during DC charging.