Vehicle Frame Resistor Braking for Excess Energy Dissipation

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Solution Overview

Problem

Existing electric vehicles face challenges in safely and cost-effectively dissipating excess electrical energy when the energy storage device is full or defective, as current methods require additional cooling circuits and can damage electrical consumers.

Innovation Solution

The vehicle utilizes its electrically conductive frame, body, or chassis as a rheostatic brake to dissipate excess energy through a controlled short circuit, eliminating the need for additional brake resistors and cooling circuits, and ensuring operational safety by avoiding electrical overload.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If brake resistors with additional cooling circuits are used to dissipate excess electrical energy, then the energy can be converted into heat and dissipated, but this leads to additional costs and energy consumption

Engineering Contradiction:

Improveexcess electrical energyVSAvoidcooling circuits

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent merges the function of heat dissipation with the vehicle's existing cooling system by integrating the brake resistor into the coolant circuit. The coolant flows through channels in the brake resistor, absorbing heat directly from the resistor elements, thereby combining two separate systems (brake resistor and cooling system) into a unified structure that eliminates additional cooling circuits

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The brake resistor is designed to serve multiple functions: it acts as both an energy dissipation device and a heat exchange component within the vehicle's cooling system. The resistor housing incorporates coolant flow channels, allowing the same structure to perform electrical energy conversion and thermal management simultaneously

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of energy

If electrical energy is supplied to electrical consumers to discharge excess energy, then the energy can be utilized, but the electrical consumers can be damaged by electrical overload

Engineering Contradiction:

Improveexcess electrical energyVSAvoidelectrical consumers

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent converts the potentially harmful excess electrical energy into beneficial thermal energy by directing it through the brake resistor. The controlled resistance converts the overload-prone electrical energy into heat, which is then safely dissipated through the coolant system, transforming a harmful situation into a useful thermal management opportunity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of energy

If a defined short circuit is generated via conductive element to convert electrical energy into heat, then the energy can be dissipated, but additional cooling circuits are required to cool the brake resistors

Engineering Contradiction:

Improveelectrical energy to heat energyVSAvoidcooling circuits

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces costs and energy consumption by leveraging the vehicle's existing structure for heat dissipation, enhancing operational safety and efficiency while avoiding damage to electrical consumers.

Implementation Method 1

the electric machine converts kinetic energy into electrical energy

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an electrically conductive vehicle part which can be used as a resistor element for converting electrical energy into heat

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12049137B2Vehicle comprising an electrically conductive vehicle part that can be used as a resistor element for converting electrical energy into heat

Publication Date: 2024.07.30 MAN TRUCK & BUS SE

AI summary

The invention relates to a vehicle, preferably a commercial vehicle, a tour coach or a city bus. The electrically drivable vehicle (1) comprises an electric machine (2) that can be operated as a generator, an accumulator for electrical energy (3), an electrically conductive vehicle part, and a control device (5). The accumulator for electrical energy (3) is designed to receive electrical energy (4) from the electric machine (2) and/or to deliver electrical energy (4) to the electric machine (2). The control device (5) is designed, when at least one predetermined energy-dissipation condition is met, to divert electrical energy (4) generated when the electric machine (2) is being operated as a generator to the electrically conductive vehicle part for conversion into thermal energy, wherein the electrically conductive vehicle part is a vehicle frame (6) and/or a vehicle body (7) and/or a bodywork (8).