Synchronous Energy Source Switching Controller for Hybrid Vehicles
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Solution Overview
Problem
Existing energy source switching systems in hybrid electric vehicles are limited by high inrush currents that can destroy switching elements, forcing power interruptions and restricting switching to only during vehicle rest, which affects vehicle performance and safety during active drive cycles.
Innovation Solution
A synchronous energy source switching controller system with a motor assembly that includes a voltage-stabilizing module, switching modules with precharge and energizing switches, and a detection module, allowing rapid and synchronized switching of energy sources during active drive cycles to prevent large inrush currents and maintain power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If energy source switching is performed during active drive cycles, then vehicle performance and safety are improved, but large inrush currents destroy switching elements
Solution Approach 1:
The system performs preliminary actions by detecting voltage differences between energy sources and the motor controller before switching occurs. When a voltage difference exceeds a threshold, the system pre-charges the switching element through a dedicated pre-charge circuit, ensuring the element is ready to handle the incoming current without damage. This preliminary preparation enables safe switching during active drive cycles.
Solution Approach 2:
A dedicated pre-charge circuit serves as an intermediary between the energy source and the switching element. This intermediate circuit includes a pre-charge switch and resistor that gradually charge the switching element, acting as a buffer that protects the switching element from direct exposure to large inrush currents while enabling the switching operation to proceed.
2Ease of operation
If switching elements are protected from inrush currents, then switching can occur during drive cycles, but switching speed is reduced due to pre-charge requirements
Solution Approach 1:
The system continuously monitors voltage differences and performs pre-charging only when necessary (when voltage difference exceeds threshold), rather than always pre-charging before every switch. This conditional preliminary action reduces unnecessary delay while still protecting against inrush currents when needed.
Solution Approach 2:
The switching system dynamically adjusts its behavior based on real-time voltage conditions. The control device continuously compares voltage differences and dynamically activates or deactivates the pre-charge circuit, allowing the system to switch rapidly when conditions permit and provide protection only when voltage differences warrant it.
3Power
If super capacitors are used for peak power delivery, then acceleration performance is improved, but energy volume density is low requiring large capacity
Solution Approach 1:
The energy storage system is segmented into multiple functional components: super capacitors for peak power bursts and battery for sustained energy delivery. This segmentation allows each component to be optimized for its specific function, with super capacitors providing high power when needed and the battery providing continuous energy, eliminating the need for oversized super capacitor banks.
Solution Approach 2:
The system uses partial action by deploying only the necessary amount of super capacitor capacity for peak power events rather than using full super capacitor banks for all operations. The battery supplements the super capacitors for sustained energy needs, allowing the super capacitors to be smaller while still meeting peak power requirements.
Data Source
AI summary
The present invention relates to a motor assembly, a method of operation thereof and a transport vehicle provided with the motor assembly. The motor assembly is provided with an energy source switching controller that is in synchronization with motor operation and provides an improved utilization of energy storage sources in an electric, hybrid electric, or fuel cell based motor vehicle drive train application.