Vehicle Drive Control Device Compact Frame Design
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Solution Overview
Problem
The increasing use of permanent magnet synchronous motors in rail vehicles necessitates a higher number of inverters and contactors, leading to larger and heavier drive control equipment with increased manufacturing costs due to the complexity and size of the power conversion systems.
Innovation Solution
The design incorporates a compact frame with integrated power conversion devices, semiconductor elements, and control boards, utilizing a cooler and orthogonal control board arrangement to minimize space and weight, along with a single contactor for multiple inverters, reducing the overall size and cost of the drive control equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If permanent magnet synchronous motors are employed to improve efficiency, then motor efficiency is improved, but the number of inverters and contactors increases leading to larger equipment size and higher manufacturing costs
Solution Approach 1:
Multiple inverters are integrated into a single compact housing structure, merging what would traditionally be separate equipment units into one consolidated device. The housing contains multiple semiconductor element assemblies, each with its own inverter circuitry, allowing multiple motor control functions in a single equipment unit rather than requiring separate inverter units for each motor.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support for multiple semiconductor element assemblies, acts as a common enclosure for electrical components, provides cooling pathways for all semiconductor elements, and serves as a mounting structure for multiple contactors. This multi-functionality reduces the need for additional specialized components.
2Use of energy by moving object
If permanent magnet synchronous motors are employed to improve efficiency, then motor efficiency is improved, but the number of inverters and contactors increases leading to higher manufacturing costs
Solution Approach 1:
Multiple contactors are integrated into the housing structure, combining what would traditionally be separate contactor units into a single equipment assembly. The housing provides mounting structures and electrical connections for multiple contactors, reducing the need for separate mounting hardware, wiring harnesses, and installation procedures that would be required for individual contactor units.
3Adaptability or versatility
If multiple inverters are provided for multiple motors, then each motor can be controlled independently, but the number of elements and contactors increases leading to larger equipment dimensions
Solution Approach 1:
The housing structure utilizes three-dimensional spatial arrangement to accommodate multiple semiconductor element assemblies and contactors. Rather than arranging components in a simple linear or planar fashion, the design employs vertical stacking, multi-level mounting surfaces, and spatial optimization within the housing volume, allowing multiple independent control circuits to coexist in a compact footprint.
4Adaptability or versatility
If multiple inverters and contactors are provided for multiple motors, then complete motor control is achieved, but the equipment mass increases
Solution Approach 1:
Multiple contactors are integrated into the housing structure, combining what would traditionally be separate contactor units into a single equipment assembly. The housing provides mounting structures and electrical connections for multiple contactors, reducing the need for separate mounting hardware, wiring harnesses, and installation procedures that would be required for individual contactor units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration minimizes the external dimensions and weight of the drive control equipment while reducing manufacturing costs by efficiently arranging components and eliminating the need for multiple contactors, thereby addressing the size and cost issues associated with previous technologies.
Implementation Method 1
a cooler in which are mounted a plurality of semiconductor elements constituting the power conversion devices
Implementation Method 2
a cooler in which are mounted a plurality of semiconductor elements
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Drive control equipment for a vehicle comprises: a plurality of power conversion devices (14) respectively connected with a plurality of motors (12) that convert DC power supplied from a DC power source (19) to AC power and output this to said motors; a control device (18) that controls the power conversion devices; a frame (60) that accommodates said power conversion devices and the control device and having a ceiling wall (62) facing below the vehicle floor; and a power unit (68) having a cooler (80) in which are installed a plurality of semiconductor elements constituting the power conversion devices; a first control board (82) provided with a first connector connected with said semiconductor elements, arranged facing the cooler; and a second control board (84) arranged in a direction orthogonal to said first control board and connected with a second connector connected with the first connector of said first control board.