Integrated Motor Winding Charging for Converter-Free EV Voltage Matching
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Solution Overview
Problem
Existing vehicle electrical systems require DC-to-DC converters to match charging station voltages with battery voltages, increasing vehicle weight and cost.
Innovation Solution
A battery management module uses the electric motor's windings to boost or buck voltage from charging sources to match the battery's predetermined voltage, eliminating the need for DC-to-DC converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If DC-to-DC converters are used to match charging station voltages with battery voltages, then voltage matching is achieved, but vehicle weight and cost increase
Solution Approach 1:
The electric motor is designed to perform dual functions: propulsion and voltage conversion during charging. By utilizing the motor's windings as an inductor in a voltage conversion circuit, the system eliminates the need for separate DC-to-DC converters, thereby reducing vehicle weight while maintaining voltage matching capability between charging stations and the battery
Solution Approach 2:
The patent combines the charging function with the existing motor structure. The motor windings are integrated into the voltage conversion circuit, merging the propulsion system and charging system into a unified architecture. This consolidation removes the need for additional converter components, directly addressing the weight issue
2Adaptability or versatility
If DC-to-DC converters are used to match charging station voltages with battery voltages, then voltage matching is achieved, but vehicle cost increases
Solution Approach 1:
The electric motor is designed to perform dual functions: propulsion and voltage conversion during charging. By utilizing the motor's windings as an inductor in a voltage conversion circuit, the system eliminates the need for separate DC-to-DC converters, thereby reducing vehicle weight while maintaining voltage matching capability between charging stations and the battery
Solution Approach 2:
The patent extracts the voltage conversion function from a separate DC-to-DC converter and integrates it into the existing motor structure. By taking out the need for additional converter components and utilizing the motor windings for this purpose, the system reduces both cost and complexity
3Weight of moving object
If additional converters are eliminated, then vehicle weight and cost are reduced, but voltage matching complexity increases
Solution Approach 1:
The motor windings automatically serve dual purposes: propulsion during vehicle operation and voltage conversion during charging. The system leverages the existing motor structure to perform voltage matching without requiring additional active control components, thereby reducing complexity despite the multi-functional requirement
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 vehicle weight and cost by directly charging the battery without the need for additional converters, while ensuring efficient voltage matching.
Implementation Method 1
an inverter module including (a) inputs connected to receive power from the battery and (b) outputs connected to the electric motor
Data Source
AI summary
A battery charging system includes: an electric motor including stator coils; a battery; a charge port configured to receive power from charging stations by wire; first and second electrical conductors connected between the battery and the charge port; an inverter module including (a) inputs connected to receive power from the battery and (b) outputs connected to the electric motor; a third electrical conductor; and a switch configured to electrically connect and disconnect a first end of the third electrical conductor to and from the first electrical conductor, where the third electrical conductor includes a second end that is connected to at least one of the stator coils via one of the outputs of the inverter module.