Power Module Intrinsic Control Units Segmentation
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Solution Overview
Problem
Existing electric vehicle power conversion systems are costly, unreliable, and require numerous components, leading to high connector and insulation needs, with no efficient way to diagnose and replace faulty components, especially when a single control unit is shared across multiple arms.
Innovation Solution
A power module with intrinsic control units capable of independent operation and data exchange with a remote control unit, reducing the need for decoupling components and allowing for intelligent control of motor supply and battery charging, with galvanic isolation and a communication bus for data exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single control unit is shared across multiple arms, then device complexity is reduced, but reliability deteriorates because a failure requires replacement of the entire converter
Solution Approach 1:
The control system is segmented into a central control unit and multiple independent intrinsic control units, each associated with specific arms. This segmentation allows individual arms to be controlled independently, so that a failure in one arm does not affect the entire system, thereby improving reliability while maintaining manageable complexity.
Solution Approach 2:
Intrinsic control units act as intermediaries between the central control unit and the power switches. Each intrinsic control unit receives commands from the central unit and independently controls its associated arms, providing isolation that prevents system-wide failures and enables modular replacement.
2Object-affected harmful factors
If multiple decoupling components are used to isolate high voltage circuits, then safety and insulation are improved, but device complexity and cost increase
Solution Approach 1:
Multiple decoupling functions are merged into the intrinsic control units. Each intrinsic control unit integrates the decoupling functionality needed for its associated arms, eliminating the need for separate decoupling components for each high-voltage-low-voltage connection and reducing overall system complexity.
Solution Approach 2:
The intrinsic control units serve multiple functions: they control power switches, provide galvanic isolation, and manage communication between the central control unit and power circuitry. This multi-functionality reduces the total number of components needed while maintaining safety and insulation requirements.
3Ease of operation
If intelligent functions are centralized in a main control unit, then ease of operation is improved, but reliability deteriorates and fault diagnosis becomes difficult
Solution Approach 1:
Intelligent functions are segmented between the central control unit and intrinsic control units. The central unit handles high-level operation and coordination, while intrinsic units handle local control and diagnostics. This segmentation improves reliability by isolating failures to specific modules while maintaining ease of operation through centralized coordination.
Solution Approach 2:
Intrinsic control units provide feedback to the central control unit about the status of their associated arms and components. This feedback mechanism enables centralized monitoring and operation while allowing local intelligence to detect and report faults, improving both reliability and ease of diagnosis.
4Ease of manufacture
If the entire converter must be replaced when a failure occurs, then manufacturing simplicity is maintained, but after-sales service cost and downtime increase
Solution Approach 1:
The converter is segmented into modular units with distinct intrinsic control units that can be independently replaced. This modular architecture maintains manufacturing simplicity through standardized modules while dramatically improving ease of repair, as only the faulty intrinsic control unit or arm needs to be replaced rather than the entire converter.
Solution Approach 2:
The modular design enables selective replacement of only the defective intrinsic control unit or arm, allowing the functional portions of the system to be recovered and continue operating. This reduces downtime and replacement costs while maintaining standardized manufacturing processes for the modular components.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a power module (9) for converting an electric current flowing between an accumulator and an alternating-current motor, said module (9) comprising switching means (10) that can be controlled to authorise the powering of the motor and/or the charging of the accumulator, and an intrinsic control unit (13) connected to said switching means (10) and capable of delivering opening and/or closing signals to said switching means (10), said intrinsic control unit (13) being further capable of exchanging data with a remote control unit, with a potential barrier. Figure for the abstract: Figure 2