Parallel Modular Converter Architecture for Electric Vehicles
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Solution Overview
Problem
Electric vehicles face challenges in efficiently distributing power to multiple motors due to the need for high-rated power converters, which increases weight and cost, as dedicated converters must be rated to handle maximum power requirements to accommodate varying traction conditions, leading to inefficiencies and unnecessary power usage.
Innovation Solution
A parallel modular converter system with a switching network that selectively connects multiple parallel power converters to electric motors based on load conditions, allowing for dynamic power distribution and reducing the total number of power converters needed while maintaining power capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated power converters are rated to handle maximum power requirements to accommodate varying traction conditions, then power capacity and reliability are improved, but weight and cost increase
Solution Approach 1:
The patent implements a dynamic power converter rating system where converters can adjust their operational capacity based on real-time traction conditions. The control system monitors wheel slip, traction quality, and power demand to dynamically reconfigure the parallel converter array, enabling each converter to operate at optimal power levels rather than being permanently rated for maximum capacity. This dynamic adaptation resolves the contradiction by maintaining reliability when needed while reducing weight-related costs through right-sizing converter ratings.
Solution Approach 2:
The system changes the operational parameters of power converters by adjusting their power ratings dynamically. Instead of fixed high ratings, the converters operate at variable power levels matched to actual demand. The control system modifies parameters such as converter switching frequency, power output magnitude, and operational state (active/standby) based on traction conditions, thereby resolving the weight-capacity contradiction through parameter optimization rather than hardware oversizing.
2Reliability
If dedicated power converters are rated to handle maximum power requirements, then power capacity is improved, but cost increases
Solution Approach 1:
The dynamic reconfiguration capability allows the system to maintain full power capacity when needed while using smaller, less expensive converters during normal operation. The control system activates additional converters only when traction conditions require maximum power output, enabling the use of lower-rated (cheaper) converters that would otherwise be insufficient. This resolves the cost-capacity contradiction by making power capacity available on-demand rather than requiring permanent high-capacity hardware for all converters.
Solution Approach 2:
The parallel converter architecture provides multi-functionality where each converter can serve multiple roles: primary power conversion, standby support, and dynamic load sharing. The converters are universally designed to handle varying power demands through software control rather than dedicated hardware configurations, reducing overall system cost while maintaining the ability to deliver maximum power capacity when all converters operate together under high-demand conditions.
3Adaptability or versatility
If separate dedicated power converters are provided for each motor, then adaptability to traction conditions is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple independent power converter systems into a single parallel converter array with unified control. Instead of completely separate dedicated converters for each motor, the system combines converters that can be dynamically allocated to different motors based on traction needs. The control system manages power distribution across the merged array, reducing overall system complexity while maintaining adaptability through centralized coordination rather than multiple independent control systems.
Solution Approach 2:
The power converter system is segmented into modular parallel units that can be independently controlled and reconfigured. Each converter in the parallel array represents a discrete, manageable module that can be individually activated or deactivated based on traction conditions. This segmentation reduces complexity by breaking down the monolithic power distribution system into smaller, standardized modules that are easier to manufacture, control, and maintain while preserving adaptability through flexible combinatorial configurations.
Data Source
Figure 1A~1B
Figure 1C
Figure 2A
AI summary
Method and apparatus for powering electric motors. The electric motors are connected to a DC power supply by a parallel modular converter that includes a plurality of parallel power converters that convert the DC power to AC power. The parallel modular converter selectively connects different parallel power converters to different ones of the electric motors to provide an adequate supply of electrical power to meet the load conditions of the electric motor. As the load conditions of the electric motors dynamically change, the parallel modular converter can selectively connect certain PPCs to different motors to satisfy the changing load conditions.