Rotary Electrical Machine Power Module Integration
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Solution Overview
Problem
Conventional rotary electrical machines for motor vehicles require bulky assemblies with multiple power modules, making it difficult to adapt to machines with reduced diameters and incorporating new functions like recuperative braking or engine assistance.
Innovation Solution
A rotary electrical machine with two integrated power modules, each comprising three rectifier bridge arms and a control unit, along with a connector for electrical connections, allowing for reduced size and easier implementation of advanced functions, and a regulation module integrated in the heat dissipater for compact assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three power modules are used for a stator with two three-phase systems, then all phases can be controlled, but the assembly becomes bulky and difficult to adapt to reduced diameter machines
Solution Approach 1:
The patent merges the functionality of three separate power modules into two integrated power modules. Each power module controls three bridge arms that can switch between rectification and inversion modes, allowing two modules to handle all six phases of the stator winding. This reduction from three to two modules directly addresses the bulkiness issue while maintaining full control capability.
Solution Approach 2:
The power modules are designed with universal functionality to perform multiple operations: rectification (converting AC to DC), inversion (converting DC to AC), and regeneration (recuperative braking). The same bridge arms and control units handle different functions by changing their operational mode based on control signals, eliminating the need for separate dedicated modules for each function.
2Ease of operation
If three power modules are used, then complete phase control is achieved, but integration with control electronics becomes more difficult and size increases
Solution Approach 1:
The control units of the two power modules are integrated with the vehicle's existing control electronics (engine computer, transmission control unit). The control units receive operating parameters from these systems and coordinate their operation through shared communication protocols, simplifying integration compared to adding three separate control systems.
Solution Approach 2:
The control units are designed to universally manage multiple functions through software control: rectification control, inversion control, regeneration control, and temperature monitoring. This multi-functional control approach reduces the need for separate dedicated control circuits for each power module and function.
3Adaptability or versatility
If three power modules are used, then all functions are covered, but new functions like recuperative braking cannot be easily incorporated
Solution Approach 1:
The power modules are designed with inherent multi-functionality that includes recuperative braking capability. The same bridge arms that perform rectification can operate in inversion mode to enable regeneration. This universal design allows easy incorporation of new functions like recuperative braking and engine assistance without requiring additional hardware, as the control unit can switch between operational modes based on vehicle requirements.
4Adaptability or versatility
If more power modules are used, then functionality is enhanced, but the heat dissipater size increases
Solution Approach 1:
The patent combines the thermal management requirements of two power modules into a single integrated heat dissipater design. The heat dissipater includes cooling channels and fins that efficiently dissipate heat from both modules simultaneously, reducing the overall volume compared to having separate heat dissipaters for each module. The compact arrangement of the two modules allows for optimized thermal coupling and heat transfer pathways.
Data Source
AI summary
The invention relates mainly to a rotary electrical machine for a motor vehicle, comprising:a heat dissipater (65);two power modules (50) integrated in the heat dissipater (65), each comprising rectifier elements (53) which form three rectifier bridge arms (52), connection terminals (58) associated with the rectifier bridge arms (52), and a control unit which can control the rectifier bridge arms; anda connector (61) which establishes electrical connections, in particular between the terminals (58) for connection of the power modules (50) and the phase outputs of the rotary electrical machine.