Parallel Power Conversion Modules for Electric Drive Noise Reduction
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Solution Overview
Problem
The existing electrified vehicle powertrains face challenges in efficiently managing high voltage and current requirements, leading to increased costs and power losses due to the need for high-current components and additional power conversion units like DC-DC converters, which also impact fuel economy.
Innovation Solution
Implementing a parallel power conversion module structure that divides the energy storage unit power into sections of an electric machine, eliminating the need for a DC-DC converter by using multiple power conversion modules to focus fields in stator teeth, thereby reducing costs and power losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single power conversion unit is used to meet high voltage and current requirements, then the system can provide sufficient power, but the system requires high-current components that increase cost and power losses
Solution Approach 1:
The patent divides the single power conversion unit into multiple parallel power conversion modules. Each module handles a portion of the total power requirement, allowing operation at lower current per module. This segmentation reduces I²R losses in each module while maintaining the required total power output capability.
2Ease of operation
If a DC-DC converter is added to convert voltage to operational levels, then the electric machine can receive appropriate voltage, but the system complexity and fuel economy are negatively impacted
Solution Approach 1:
The parallel power conversion modules are designed to perform multiple functions: they directly provide both voltage conversion and power delivery to the electric machine. By making each module multi-functional, the system eliminates the need for a separate DC-DC converter, reducing overall system complexity while maintaining voltage conversion capability.
3Power
If high-current components are used to meet power requirements, then sufficient power can be delivered, but the cost of the system increases
Solution Approach 1:
By segmenting the power conversion system into multiple parallel modules, each module operates at lower current levels. This allows the use of smaller, less expensive components in each module compared to a single high-current system, thereby reducing overall system cost while maintaining the required power delivery capability.
4Adaptability or versatility
If additional power conversion units are added to the system, then power conversion flexibility is improved, but packaging efficiency is reduced
Solution Approach 1:
The patent combines multiple power conversion modules into a single integrated power conversion system with a shared control unit. This merging approach provides the flexibility of multiple conversion units while consolidating the physical footprint, improving packaging efficiency compared to having separate discrete units.
Data Source
AI summary
An electric machine is configured with at least two sets of phase windings. A plurality of power switches is configured to selectively couple voltage terminals to each of the phase windings. A controller is programmed to operate the power switches according to a switching pattern, for each of the sets, updated at intervals defined by a switching frequency such that the switching patterns are different during each one of the intervals.