Description:FIELD OF THE INVENTION
[0001] The present invention relates to an integrated power electronics system configured for application in vehicles. Particularly, the present invention focuses on enhancing efficiency and reducing system complexity with an integrated power electronics system for electrical vehicles that encompasses the consolidation of an onboard charger, a DC-DC converter, a motor controller, and a lighting control unit into a single module, facilitating streamlined design and optimized power management within the vehicle architecture.
BACKGROUND OF THE INVENTION
[0002] The integrated power electronics in vehicles, particularly electric vehicles (EVs), are undergoing rapid development. This area includes systems that govern power management, motor control, and lighting functionalities within electric vehicles. Traditionally, each of these systems has been developed as a separate module, resulting in a multitude of standalone components within a vehicle. Such discrete configurations, while effective, often lead to increased complexity in system design, higher production costs, and excessive wiring within the vehicle. Additionally, the spatial and thermal considerations associated with multiple standalone components necessitate intricate design strategies to ensure operational efficiency and safety.

[0003] Existing technologies in the power electronics domain for vehicles have traditionally dealt with separate and distinct modules for onboard charging, DC-DC conversion, motor control, and lighting management. The onboard charger (OBC) is used to convert alternating current (AC) from an external source into direct current (DC) to recharge the high-voltage battery(400V) of the EV, whereas the DC-DC converter steps down this DC voltage(400V) to 12V for other systems in the vehicle.. However, employing separate systems for these functionalities can contribute to inefficiencies such as power loss, increased weight, and substantial space requirements within vehicles.

[0004] Motor control systems in electric vehicles have conventionally utilized various configurations to manage motor operation, often leading to a lack of coordinated control. The motor controllers using techniques such as H-Bridge circuits to effectuate direction and speed changes in the vehicle's motor. Yet, maintaining optimum performance across disparate motor control units is challenging, with potential for redundancy and reduced overall system effectiveness. Similarly, lighting control systems, though critical for safety and usability, face difficulties in integrated management, involving complex wiring and often inefficient light modulation schemes.

[0005] Limitations associated with these traditional configurations include the complexity of system interconnections, increased material use due to wiring and connectors, and challenges in coordinating component communication. These factors lead to potential inefficiencies in power distribution and complicate fault management, as isolated systems require separate diagnostic and protection mechanisms.

[0006] There is a need to address these inefficiencies and limitations by consolidating these disparate functionalities into a cohesive system. The present integrated power electronics system addresses this need by combining the functions of the onboard charger, DC-DC converter, motor controller, and lighting control unit into a single module. This integration seeks to enhance efficiency, simplify vehicle architecture, reduce electrical complexity, and optimize the overall design, thereby overcoming the challenges presented by conventional systems.
OBJECTIVES OF THE INVENTION
[0007] The primary objective of the present invention is to provide a system integrating onboard charging, DC-DC conversion, motor control, and lighting management into a single module for electric vehicles, thereby enhancing operational efficiency and streamlining vehicle electrical design.

[0008] Another objective of the present invention is to implement high-efficiency power management across vehicle systems by consolidating power distribution stages, reducing material requirements, and optimizing energy flow.

[0009] Another objective of the present invention is to enable effective bi-directional control of electric motors by employing a MOSFET-based H-Bridge circuit within the integrated system module.
[0010] Another objective of the present invention is to achieve isolated control of the vehicle's lighting systems, using microcontroller-based management and pulse-width modulation control to facilitate accurate brightness adjustments and system safety.

[0011] Yet another objective of the present invention is to enhance vehicular safety and reliability by providing centralized fault management capable of addressing overvoltage, short circuits, and thermal challenges within the integrated power electronics system.

[0012] Yet another objective of the present invention is to improve thermal management through the integration of dedicated thermal zones, ensuring effective heat dissipation across high and low-power electronic components.

[0013] Yet another objective of the present invention is to facilitate communication and control within the integrated system through low-latency signal routing, enhancing real-time responsiveness and system coordination.

SUMMARY OF THE INVENTION
[0014] The present invention relates to an integrated power electronics system (100) designed for use in electric vehicles (EVs), aiming to consolidate multiple functionalities within a single module to improve efficiency and simplify vehicle design. This system comprises an onboard charger (OBC), DC-DC converter, motor controller, and lighting control unit, each serving distinct roles in the vehicle's power management architecture. The OBC receives AC power and converts it to DC for the vehicle's high-voltage battery, while the DC-DC converter reduces the high-voltage DC to lower voltage for other systems. The motor controller uses a MOSFET-based H-Bridge circuit for motor direction control, and the lighting control unit manages lighting systems through microcontroller and PWM signal-controlled MOSFET drivers.

[0015] The integration of these components provides a unified module, addressing traditional inefficiencies associated with separate systems. This integration minimizes the complexity of system interconnections, reduces material use by decreasing wiring and connectors, and enhances overall power distribution efficiency. By employing shared power stages and centralized fault management, the system optimizes operation and safety with streamlined thermal management and low-latency signal routing. This consolidated approach thus represents an advancement over traditional configurations by enhancing system performance and reducing production costs and design complexity in electric vehicles.

BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:

[0017] Fig. 1 illustrates a block diagram of an integrated power electronics system in a car, showing the connections between a 400V battery, a DC/DC converter with OBC, a motor controller, and a light control module.

[0018] Fig. 2 illustrates a schematic diagram of the DC-DC and OBC circuitry illustrating the conversion process from AC-DC and DC-DC stages.

[0019] Fig. 3 illustrates a schematic diagram of a MOSFET H-Bridge motor controller used to manage motor operation.

[0020] Fig. 4 illustrates a block diagram of the light control module, depicting the communication and power connections from the DC-DC converter to various peripherals.

[0021] Other objects and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The following description describes various features and functions of the disclosed system with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.

[0023] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0024] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0025] The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purpose only and not for the purpose of limiting the invention.

[0026] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0027] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, steps or components but does not preclude the presence or addition of one or more other features, steps, components or groups thereof.

[0028] The present invention relates to an integrated power electronics system (100) designed for use in electric vehicles (EVs). This system is configured to consolidate multiple functional components, including the onboard charger (OBC) (101), DC-DC converter (102), motor controller (103), and lighting control unit (104), into a single power electronics module. Such integration aims to enhance efficiency and streamline the vehicle's power management architecture, subsequently reducing system complexity and design considerations.

[0029] The system comprises several components, each contributing to the overall functionality of the single power electronics module. These components operate in a synergistic manner, enabling efficient power management and control within the EV's infrastructure. The power electronics module, comprises:

[0030] On-Board Charger (OBC) (101) and DC-DC Converter (102)

[0031] OBC Functionality: The OBC (101) is responsible for receiving AC power from an external charging port. It converts this AC power into DC power suitable for charging the vehicle's high-voltage battery, rated at 400V. This conversion process is crucial in maintaining the charge level necessary for vehicle operation.

[0032] DC-DC Conversion: Integrated within the same module, the DC-DC converter (102) operates to step down the high-voltage DC (400V) to lower voltages such as 12V or 13.8V DC. This lower voltage is required for powering various systems in the vehicle, including lighting and control electronics. The DC-DC conversion utilizes high-frequency switching techniques to achieve improved efficiency and reduced power losses, ensuring optimal performance.

[0033] Motor Controller: The motor controller (103) employs a MOSFET-based H-Bridge circuit configuration. This strategic design facilitates the bi-directional control of the electric motor, essential for managing vehicle dynamics. The controller manages alternating control signals to enable forward and reverse operation of the motor, allowing for precise coordination of acceleration, braking, and directional changes. The MOSFET-based approach provides enhanced reliability and efficiency during motor control processes.

[0034] Lighting Control Unit (104 ): The lighting control unit, comprises:

[0035] Microcontroller Management: The lighting control unit (104) incorporates a microcontroller to drive both exterior and interior lighting systems. Each lighting circuit is electrically isolated from others, contributing to system safety by ensuring that a fault in one circuit does not propagate to others.
[0036] Brightness Control: The control unit employs MOSFET drivers actuated by a pulse-width modulation (PWM) signal to regulate brightness. This approach facilitates smooth dimming transitions and eliminates flickering while maintaining energy efficiency throughout lighting operations.

[0037] In an embodiment, the integrated module leverages shared power stages to optimize energy distribution across the vehicle systems. This approach not only minimizes material usage by reducing wiring requirements but also lowers the potential for voltage drops, thus improving overall efficiency.

[0038] Exemplary embodiments may involve variations in the configuration of the motor controller (103) to accommodate different types of electric motors, such as permanent magnet synchronous motors (PMSMs) or induction motors, further demonstrating the versatility of the integrated system.

[0039] In a preferred embodiment, a power electronics system (100) for use in electric vehicles, comprising: an onboard charger (101) configured to receive alternating current (AC) power and convert AC power into direct current (DC) power for charging a high-voltage battery; a DC-DC converter (102) configured to reduce the high-voltage DC to a lower voltage level for powering other systems; motor controller unit (103) comprising a MOSFET-based H-Bridge circuit for enabling bi-directional motor control, managing vehicle acceleration, braking, and directional changes; a lighting control unit (104) comprising a microcontroller for managing exterior and interior lighting systems, exterior and interior lighting circuit being electrically isolated from each other, and controlled by pulse-width modulation (PWM)-driven MOSFET drivers for regulating brightness.

[0040] A method for integrating power electronic module within an electric vehicle, comprising:

i. receiving AC power through an onboard charger (OBC) (101) and converting said AC power to 400V DC for battery charging;
ii. reducing 400V DC to a lower voltage level using a DC-DC converter (102) to power other systems;
iii. employing a MOSFET-based H-Bridge circuit in motor control unit (103 ) to enable bi-directional motor operation for managing vehicle dynamics;
iv. managing lighting systems via a microcontroller-based lighting control unit (104), where each lighting circuit is isolated and brightness is controlled using PWM-driven MOSFET drivers;
v. ensuring centralized fault management for protection against overvoltage, short-circuits, and thermal issues, thereby enhancing system safety and reliability;
vi. implementing shared power stages to optimize energy distribution and power efficiency across the integrated module;
vii. configuring dedicated thermal zones for effective heat management;
viii. enhancing communication and control within the module through low-latency signal routing.

[0041] Integrating these components into a single module presents multiple advantages, comprising:
i) Reduction in Complexity: By combining the OBC (101), DC-DC converter (102), motor controller (103), and lighting control unit (104) within a singular unit, the system minimizes the number of separate components, resulting in reduced wiring complexity and lower production costs.
ii) Efficiency in Power Distribution: Shared power stages and shorter power pathways enhance efficiency by minimizing voltage drops and dissipative losses, leading to improved performance metrics.
iii) Enhanced Safety: The centralized fault management system provides comprehensive protection against overvoltage, short circuits, and thermal issues, thereby ensuring reliable and safe operation within the vehicle.
iv) Streamlined Thermal Management: The design accommodates dedicated thermal zones to manage heat dissipation effectively, catering to both high-power electrically demanding components and more sensitive electronics.
v) Improved Communication and Control: Low-latency signal routing within the module facilitates responsive control of the motor and lighting systems, enhancing overall driveability and driver experience.

[0042] The integrated power electronics system (100) offers a cohesive solution for power management, motor control, and lighting within electric vehicles, optimizing the system's performance, efficiency, and reliability while mitigating the limitations of conventional configurations.

[0043] The primary issue addressed by the disclosed technology is the inefficiency and complexity inherent in traditional electric vehicle power electronics architectures, which utilize distinct and separate units for each functionality such as the onboard charger (OBC)(101), DC-DC converter (102), motor controller (103), and lighting control unit (104). The independent operation of these components results in increased material usage, complex wiring requirements, and potential inefficiencies in power distribution. Moreover, standalone components can complicate thermal management and fault diagnostics, presenting additional design and cost challenges. The disclosed system solves these problems by integrating multiple functionalities into a unified module, thereby streamlining design, reducing production costs, and enhancing operational efficiency and safety.

[0044] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:1. A power electronics system (100) for use in electric vehicles, comprising:
a) an onboard charger (101) configured to receive alternating current (AC) power and convert AC power into direct current (DC) power for charging a high-voltage battery;
b) a DC-DC converter (102) configured to reduce the high-voltage DC to a lower voltage level for powering other systems in the vehicle;
c) a motor controller (103) comprising a MOSFET-based H-Bridge circuit for enabling bi-directional motor control, managing vehicle acceleration, braking, and directional changes;
d) a lighting control unit (104) comprising a microcontroller for managing exterior and interior lighting systems, exterior and interior lighting circuit being electrically isolated from each other, and controlled by pulse-width modulation (PWM)-driven MOSFET drivers for regulating brightness;
e) the system is configured to integrate onboard charger (OBC) (101), DC-DC converter (102), motor controller (103), and lighting control unit (104), into a single power electronics module.
2. The power electronics system (100) as claimed in claim 1, wherein the DC-DC converter (102) employs high-frequency switching technique for improved efficiency and reduced power losses.
3. The power electronics system (100) as claimed in claim 1, wherein the motor controller (103) is adaptable for use with different types of electric motors, including permanent magnet synchronous motors (PMSMs) and induction motors.
4. The power electronics system (100) as claimed in claim 1, wherein the power electronics module includes shared power stages for optimized energy distribution, effectively minimizing material usage and reducing the potential for voltage drops.
5. The power electronics system (100) as claimed in claim 1, wherein the power electronics module comprising a centralized fault management system providing protection against overvoltage, short-circuits, and thermal issues to enhance system safety and reliability.
6. The power electronics system (100) as claimed in claim 1, wherein the power electronics module incorporates dedicated thermal zones for effective heat management, catering to components with varying thermal demands.
7. The power electronics system (100) as claimed in claim 1, wherein low-latency signal routing within the module facilitates responsive communication and control of motor and lighting systems.
8. A method for integrating a power electronics module within an electric vehicle, comprising:
a) receiving AC power via an onboard charger (101) and converting it to high-voltage DC power for the battery;
b) converting the high-voltage DC to a lower voltage level using a DC-DC converter (102) for other systems;
c) employing a MOSFET-based H-Bridge circuit in motor control unit (103 ) for bi-directional motor operation;
d) using a microcontroller-based lighting control unit (104) to manage lighting systems, isolate circuits, and control brightness via PWM-driven MOSFET drivers;
e) implementing centralized fault management for protection against operational hazards;
f) utilizing shared power stages for energy distribution efficiency;
g) configuring thermal zones for heat management;
h) enhancing module communication and control through optimized signal routing.
9. The method as claimed in claim 8, wherein the motor controller (103) configuration is adjustable to accommodate various motor types, enhancing the versatility of the integrated system.