DUAL INVERTER INTEGRATED CHARGER WITH SYNCHRONOUS MOTORS HAVING OPEN-END WINDING CONFIGURATION
The present disclosure relates to an integrated charger unit that utilizes variable flux memory motors (VFMMs) with an open-end winding configuration and a dual inverter setup comprising a first inverter and a second inverter. The charger improves performance of the VFMMs by applying higher winding voltage through use of multiple inverters. The VFMMs are operable in both driving and charging modes without requiring high-current switches, reducing system size, cost, and complexity. In the charging mode, windings of the VFMMs serve as filter inductors to smooth AC-to-DC conversion, facilitating battery charging via the first inverter. The charger unit is fault-tolerant, cost-efficient, and eliminates the need for a separate onboard charger, leveraging the bidirectional nature of the dual inverters for efficient energy utilization.
1 . An vehicle having an Integrated Power Electronics Unit (“IPEU) and a battery for storing power from a power source, the IPEU comprising:
at least one synchronous motor having at least two phase windings in Open End Winding
configuration, each winding having at a first and a second end;
at least a first and a second inverter, wherein
the first inverter operably couples with the first end of each of the at least two
phase windings, and operably configures bidirectional power flow between the
battery and the at least one synchronous motor; and
the second inverter operably couples with the second end of each of the at least
phase windings and the power source; and
wherein the at least one synchronous motor is operably configured as a filter inductor between the power source and the first inverter in a charging mode.
2 . The vehicle of claim 1 , wherein the IPEU comprises at least a charging mode and a driving mode, and wherein:
in the charging mode, the at least one synchronous motor is operably configured to allow
power to flow between the power source and the battery; and
in the driving mode, the battery is operably configured to allow power to flow to the at
least one synchronous motor.
3 . The vehicle of claim 2 , wherein the at least one voltage comprises a winding voltage from the first inverter and the second inverter.
4 . The vehicle of claim 3 , wherein the at least one synchronous motor being operably configured to generate torque on corresponding with at least one voltage from the second inverter in a driving mode.
5 . The vehicle of claim 4 , wherein the second inverter operably modulates the at least one voltage across the at least two phase windings of the at least one synchronous motor.
6 . The vehicle of claim 5 , wherein the IPEU operably shifts between charging mode and driving mode according to a magnetization state of the at least one synchronous motor.
7 . The vehicle of claim 6 , wherein the at least one synchronous motor comprises at least one rotor magnet having a magnetization operably adjusted by passing a pulse to magnetized or de-magnetized the at least rotor magnet.
8 . The vehicle of claim 7 , wherein the at least one synchronous motor comprises at least one soft-ferromagnetic material, and a magnetization state of the at least soft ferromagnetic material operably adjustable by a pulse of electric current to enable dynamic torque control.
9 . The vehicle of claim 8 , wherein the at least one synchronous motor comprises at least one of a Variable Flux Memory Motor (VFMM) or a Wound Field Synchronous Motor (“WFSM”).
10 . The vehicle of claim 9 , further comprising a step-down transformer that operably lowers the power flow to the battery.
11 . An Integrated Power Electronics Unit (“IPEU) having a battery for storing power from a power source, the IPEU comprising:
at least one VFMM having at least two phase windings in Open End Winding configuration, each winding having at a first and a second end;
at least a first and a second inverter, wherein
the first inverter operably couples with the first end of each of the at least two
phase windings, and operably configures bidirectional power flow between the
battery and the at least one VFMM; and
the second inverter operably couples with the second end of each of the at least
phase windings and the power source;
wherein the at least one VFMM is operably configured as a filter inductor between the
power source and the first inverter in a charging mode; and
wherein the IPEU comprises at least a charging mode and a driving mode such that in the charging mode, the at least one VFMM is operably configured to allow power to flow between the power source and the battery; and
in the driving mode, the battery is operably configured to allow power to flow to
the at least one VFMM.
12 . The IPEU of claim 11 , wherein the at least VFMM being operably configured to generate torque on corresponding with at least one voltage from the second inverter in a driving mode.
13 . The IPEU of claim 12 , wherein the at least one voltage comprises a winding voltage from the first inverter and the second inverter.
14 . The IPEU of claim 13 , wherein the second inverter operably modulates the at least one voltage across the at least two phase windings of the at least one VFMM.
15 . The IPEU of claim 14 , wherein electrical connections between the second end and the power source are operably activated and electrical connections between the second end and the second inverter are operably deactivated in the charging mode.
16 . The IPEU of claim 15 , wherein the at least one VFMM comprises at least one rotor magnet having a magnetization operably adjusted by passing a pulse to magnetized or de-magnetized the at least rotor magnet.
17 . The IPEU of claim 11 , wherein the first inverter is operably configured to convert at least one of: a single-phase or three-phase alternating current (AC) from the power source into direct current (DC) to charge the battery.
18 . The IPEU of claim 11 , further comprising an electromagnetic interference (EMI) filter positioned between the power source and the at least one VFMM, wherein the EMI filter is operably configured to reduce electrical noise in the integrated charging and driving unit in the charging mode.
19 . The IPEU of claim 11 , wherein the battery is operably configured to store electric power from the power source during the charging mode, and supply electric power to the at least one synchronous motor through the first and second inverters during the driving mode.
20 . The IPEU of claim 11 , wherein the second inverter is operably configured to supplement winding voltage provided to the at least one VFMM during the driving mode.