Power Converter Control System Signal Serialization
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Solution Overview
Problem
Conventional power converter control systems for electric powertrains face reliability issues due to external noise and ground loops, and they are cumbersome for remote placement of electronic control modules due to excessive wiring, with existing solutions not effectively serializing or deserializing commutation and communication signals for electronic switches in power electronics modules.
Innovation Solution
A power converter control system that includes a power electronics module configured to serialize and de-serialize commutation and communication signals, allowing for efficient conversion and conditioning of electrical current, and enabling remote placement of controllers by reducing wiring through serialization of signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wires are used for controlling and communicating to each electronic switch within a power electronics module, then the control system can reliably send signals to each switch, but the wiring becomes excessive and makes remote placement of electronic control modules difficult
Solution Approach 1:
The patent combines multiple control and communication signals into a single serialized data stream transmitted over one wire. The controller multiplexes multiple signals (commutation signals, status requests, error messages) onto a single communication channel, eliminating the need for separate wires for each signal type while maintaining reliable transmission to the power electronics module.
Solution Approach 2:
The patent introduces a serialization/deserialization interface as an intermediary between the controller and power electronics module. This intermediary converts parallel multiple-wire signals into a serialized single-wire communication protocol, enabling remote placement while preserving signal integrity through protocol-level error checking and validation.
2Reliability
If multiple wires are used for controlling electronic switches, then each critical signal can be transmitted independently, but the system becomes vulnerable to external noise and ground loops
Solution Approach 1:
The patent merges multiple independent signal lines into a single differential communication bus. By combining control signals, status signals, and communication data into one serialized stream transmitted over a shielded differential pair, the system reduces the surface area exposed to external noise and eliminates ground loop issues that plague multi-wire systems.
Solution Approach 2:
The patent replaces the mechanical/electrical multi-wire connection system with a digital serialized communication protocol. Instead of relying on multiple physical wire connections that are susceptible to electromagnetic interference, the system uses protocol-based error detection, validation, and retransmission mechanisms to ensure reliable communication over a single noise-resistant channel.
3Device complexity
If existing solutions serialize vehicle data bus signals, then wiring complexity is reduced, but they cannot serialize or deserialze commutation and communication signals for electronic switches in power electronics modules
Solution Approach 1:
The patent creates a universal serialization interface that handles multiple signal types through a single protocol. The same serialized communication channel carries both vehicle data bus signals and power electronics control/communication signals, with the controller intelligently multiplexing different signal types and the power electronics module deserializing and routing them to appropriate internal destinations.
Solution Approach 2:
The patent segments the communication protocol into distinct message types within the serialized stream. Different signal types (commutation commands, status requests, error messages, parameter updates) are packaged as separate protocol messages with unique identifiers, allowing the single-wire interface to handle diverse signal types without requiring dedicated wires for each function.
Data Source
AI summary
A power converter control system for electric powertrains is disclosed. The power converter control system may include at least one power producing device and at least one power consuming device. The power converter control system may further include at least one power electronics module configured to convert and condition a flow of electrical current between the at least one power producing device and the at least one power consuming device. The at least one power electronics module may further be configured to serialize a flow of a first set of signals between the at least one power electronics module and at least one controller. The first set of signals may correspond to at least one characteristic of the at least one power electronics module.