Power converter system and non-transitory computer readable medium

Abstract

A power converter system and a non-transitory computer readable medium, the power converter system comprising: an input configured to receive input AC power from an input power source, the input power source having a peak voltage limit; at least one output terminal configured to provide output power to at least one load; a charger coupled to the input and configured to convert the input AC power to first DC power; a DC bus configured to receive the first DC power; at least one power converter configured to convert DC power from the DC bus to output power; and an auxiliary power source coupled to the DC bus and configured to provide second DC power to the DC bus to supplement the first DC power provided by the charger in response to a voltage demand of at least one load exceeding a peak voltage limit of the input power source. The invention can overcome at least one defect in the prior art.

Description

[0001] This application is a divisional application of application number 202111214325.6, application date October 19, 2021, and invention name “New method for overcoming circuit voltage and current limitations”. Technical Field

[0002] The present disclosure generally relates to power converter systems. Background Art

[0003] Typical electrical wiring systems are configured to provide standard power input (e.g., 120V, 15A) to standard electrical devices. However, non-standard electrical devices may require more power than the standard power input. For example, the peak power demand of some non-standard electrical devices is higher than the standard power input and higher than the average power consumption of the devices. Therefore, to power non-standard electrical devices that operate at higher peak currents and / or voltage levels than standard devices, the electrical wiring system may have to be reconfigured. In such cases, the wiring system can be redesigned or completely replaced to support the higher peak power demand; however, this can be relatively time-consuming and expensive. Summary of the Invention

[0004] At least one aspect of the present disclosure relates to a power converter system comprising: an input terminal configured to receive input AC power from an input power source having a peak voltage limit; at least one output terminal configured to provide output power to at least one load; a charger coupled to the input terminal and configured to convert the input AC power into a first DC power having a first voltage level; a DC bus coupled to the charger and configured to receive the first DC power having a first voltage level; at least one power converter coupled to the DC bus to convert DC power from the DC bus into output power and provide the output power to the at least one load; and an auxiliary power source coupled to the DC bus and configured to provide a second DC power having the first voltage level to the DC bus to supplement the first DC power provided by the charger in response to a voltage demand of at least one load exceeding the peak voltage limit of the input power source.

[0005] In one embodiment, the auxiliary power source is further configured to receive first DC power having the first voltage level from the DC bus for charging when the voltage demand of the at least one load is less than the peak voltage limit of the input power source. In some embodiments, the power converter system further comprises: a power flow control module coupled to the charger, the auxiliary power source, and the DC bus; and a controller configured to: monitor the voltage demand of the at least one load relative to the peak voltage limit of the input power source; in response to the voltage demand of the at least one load being less than the peak voltage limit of the input power source, control the power flow control module to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source; and in response to the voltage demand of the at least one load exceeding the peak voltage limit of the input power source, control the power flow control module to draw second DC power having the first voltage level from the auxiliary power source.

[0006] In certain embodiments, the controller is further configured to adjust the peak voltage limit based on at least one of the variability of the input power source, utility costs, and user preferences. In various embodiments, the at least one power converter includes at least one inverter configured to convert DC power from the DC bus into AC output power. In some embodiments, the voltage level of the AC output power is greater than the peak voltage limit of the input power source. In one embodiment, the at least one power converter includes: a DC / DC converter coupled in series with the at least one inverter and configured to convert DC power from the DC bus into DC power having a different voltage level.

[0007] In some embodiments, the at least one power converter includes at least one DC / DC converter configured to convert DC power from the DC bus into DC output power. In certain embodiments, the voltage level of the DC output power is greater than the peak voltage limit of the input power source. In various embodiments, the auxiliary power source includes one or more batteries.

[0008] Another aspect of the present disclosure relates to a power converter system comprising: an input terminal configured to receive input AC power from an input power source having a peak current limit; at least one output terminal configured to provide output power to at least one load; a charger coupled to the input terminal and configured to convert the input AC power into a first DC power having a first voltage level; a DC bus coupled to the charger and configured to receive the first DC power having a first voltage level; at least one power converter coupled to the DC bus to convert DC power from the DC bus into output power and provide the output power to the at least one load; and an auxiliary power source coupled to the DC bus and configured to provide a second DC power having the first voltage level to the DC bus to supplement the first DC power provided by the charger in response to a current demand of at least one load exceeding the peak current limit of the input power source.

[0009] In one embodiment, the auxiliary power source is further configured to receive first DC power having the first voltage level from the DC bus for charging when the current demand of the at least one load is less than the peak current limit of the input power source. In some embodiments, the power converter system further comprises: a power flow control module coupled to the charger, the auxiliary power source, and the DC bus; and a controller configured to: monitor the current demand of the at least one load relative to the peak current limit of the input power source; in response to the current demand of the at least one load being less than the peak current limit of the input power source, control the power flow control module to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source; and in response to the current demand of the at least one load exceeding the peak current limit of the input power source, control the power flow control module to draw second DC power having the first voltage level from the auxiliary power source.

[0010] In certain embodiments, the controller is further configured to adjust the peak current limit based on at least one of the variability of the input power source, utility costs, and user preferences. In various embodiments, the at least one power converter includes at least one inverter configured to convert DC power from the DC bus into AC output power. In some embodiments, the current level of the AC output power is greater than the peak current limit of the input power source. In some embodiments, the at least one power converter includes: a DC / DC converter coupled in series with the at least one inverter and configured to convert DC power from the DC bus into DC power having a different voltage level.

[0011] In some embodiments, the at least one power converter includes at least one DC / DC converter configured to convert DC power from the DC bus into DC output power. In one embodiment, the current level of the DC output power is greater than the peak current limit of the input power source.

[0012] Another aspect of the present disclosure relates to a non-transitory computer-readable medium having stored thereon a sequence of computer-executable instructions for operating a power converter system. The sequence of computer-executable instructions includes instructions for instructing at least one processor to control the power converter system to: receive input AC power at an input terminal from an input power source, the input power source having a peak voltage limit and a peak current limit; operate a charger coupled to the input terminal to convert the input AC power into a first DC power having a first voltage level; provide the first DC power having the first voltage level to a DC bus; operate at least one power converter coupled to the DC bus to convert the DC power from the DC bus into output power and provide the output power to at least one load; and, in response to a voltage or current demand of the at least one load exceeding a peak voltage limit or a peak current limit of the input power source, provide a second DC power having the first voltage level from an auxiliary power source to the DC bus to supplement the first DC power provided by the charger.

[0013] Another aspect of the present disclosure relates to a method of assembling a power converter system. The method includes providing a charger configured to be coupled to an input power source, the charger configured to receive input AC power and convert the input AC power into a first DC power having a first voltage level; coupling a DC bus to the charger, the DC bus configured to receive the first DC power having the first voltage level; coupling at least one power converter to the DC bus, the at least one power converter configured to convert DC power from the DC bus into output power and provide the output power to at least one load; and coupling an auxiliary interface to the DC bus, the auxiliary interface configured to be coupled to an auxiliary power source to receive a second DC power having the first voltage level from the auxiliary power source, and providing the second DC power to the DC bus to supplement the first DC power provided by the charger in response to a voltage or current demand of the at least one load exceeding a peak voltage limit or a peak current limit of the input power source.

[0014] Another aspect of the present disclosure is a method for operating a power converter system. The method includes: receiving input AC power at an input terminal from an input power source, the input power source having a peak power limit corresponding to an input voltage level and an input current level of the input AC power; operating a charger coupled to the input terminal to convert the input AC power into a first DC power having a first voltage level; providing the first DC power having the first voltage level to a DC bus; operating at least one power converter coupled to the DC bus to convert the DC power from the DC bus into output power and providing the output power to at least one load; and in response to a power demand of the at least one load exceeding the peak power limit of the input power source, providing a second DC power having the first voltage level from an auxiliary power source to the DC bus to supplement the first DC power provided by the charger.

[0015] In one embodiment, the peak power limit corresponds to an input voltage level and an input current level of the input AC power. In some embodiments, the method includes adjusting the peak power limit based on at least one of the variability of the input power source, utility costs, and user preferences. In certain embodiments, the method includes providing a first DC power having a first voltage level from a DC bus to charge an auxiliary power source while a power demand of at least one load is less than a peak power limit of the input power source. In various embodiments, the method includes: monitoring the power demand of at least one load relative to the peak power limit of the input power source; in response to the power demand of at least one load being less than the peak power limit of the input power source, controlling the power flow control module to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source; and in response to the power demand of at least one load exceeding the peak power limit of the input power source, controlling the power flow control module to draw a second DC power having the first voltage level from the auxiliary power source.

[0016] In some embodiments, operating at least one power converter to convert DC power from a DC bus into output power further includes: operating at least one inverter configured to convert DC power from the DC bus into AC output power. In various embodiments, the at least one inverter is operated such that at least one of a voltage level and a current level of the AC output power is greater than an input voltage level and / or an input current level of the input AC power. In certain embodiments, operating at least one power converter to convert DC power from a DC bus into output power further includes: operating at least one DC / DC converter to convert DC power from the DC bus into DC output power. In one embodiment, the at least one DC / DC converter is operated such that at least one of a voltage level and a current level of the DC output power is greater than an input voltage level and / or an input current level of the input AC power. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Various aspects of at least one embodiment are discussed below with reference to the accompanying drawings, which are not intended to be drawn to scale. The accompanying drawings are included to provide illustration and a further understanding of the various aspects and embodiments and are incorporated into and constitute a part of this specification but are not intended to define the limitations of the invention. In the drawings, each identical or nearly identical component illustrated in various figures is represented by a like numeral. For clarity, not every component may be labeled in every figure. In the drawings:

[0018] Figure 1 is a functional block diagram of a power converter system according to aspects described herein;

[0019] Figure 2 is a flow chart corresponding to the operation of a power converter system according to aspects described herein;

[0020] Figure 3 is a schematic diagram of a power converter system according to aspects described herein;

[0021] Figure 4 is a functional block diagram of a power converter system according to aspects described herein; and

[0022] Figure 5 is a flow chart corresponding to the assembly of a power converter system according to aspects described herein. DETAILED DESCRIPTION

[0023] The examples of the methods and systems discussed herein are not limited to the application of the details of construction and component arrangement set forth in the following description or illustrated in the accompanying drawings. The methods and systems can be implemented in other embodiments and can be practiced or executed in various ways. The examples of specific implementations provided herein are for illustrative purposes only and are not intended to be limiting. In particular, the actions, components, elements, and features discussed in conjunction with any one or more examples are not intended to be excluded from similar effects in any other examples.

[0024] In addition, the words and terms used herein are for descriptive purposes and should not be considered limiting. Any reference to an example, embodiment, component, element, or action of a system and method mentioned herein in the singular may also include multiple embodiments, and any plural reference to any embodiment, component, element, or action herein may also include only the singular embodiment. References in the singular or plural form are not intended to limit the currently disclosed systems or methods, their components, actions, or elements. The use of "including," "comprising," "having," "containing," "involving," and their variations herein is intended to cover the items listed thereafter and their equivalents, as well as additional items. References to "or" may be interpreted as inclusive, so any term described using "or" may represent any of the described single, multiple, and all terms. In addition, if there is a discrepancy in the usage of terms between this document and the documents incorporated herein by reference, the usage of terms in the incorporated references supplements the usage of terms in this document; for irreconcilable inconsistencies, the usage of terms in this document controls.

[0025] The wiring system is typically configured to provide power from a power source (e.g., a utility grid) to electrical devices inside and outside a building. As described above, in at least one example, a standard electrical device is a device that operates at a peak power demand that is lower than the maximum power provided by the standard input power. These standard electrical devices can be plugged into a power outlet of the electrical wiring system to receive standard input power (e.g., 120V, 15A) from the wiring infrastructure. In some examples, each electrical device plugged into the standard power output includes a power converter that converts the standard input power into AC or DC device power. In other examples, each electrical device can include an external power adapter configured to convert the standard input power into device power.

[0026] In some examples, non-standard electrical devices are capable of operating with peak power demands exceeding the maximum power provided by standard input power. To support non-standard electrical devices that can operate at higher peak current and / or voltage levels than standard input power provides, the wiring system may need to be redesigned or replaced to provide higher peak power capabilities. This effort can be costly and time-consuming. Therefore, it may be advantageous to use alternative methods to increase the peak power capabilities of standard wiring systems and power supplies.

[0027] A power converter system configured to increase the peak power capability of a standard electrical system is provided herein. In at least one embodiment, the power converter system includes an auxiliary power source configured to supplement input power provided from an input power source. In one example, the power converter system can provide output power having a peak power level that exceeds the peak power limit of the input power source.

[0028] Figure 1 is a functional block diagram of a power converter system 100 according to aspects described herein. As shown, the power converter system 100 includes an input 102, a charger 104, a DC bus 106, an auxiliary power source 108, a plurality of power converters 110, and a plurality of outputs 112. In some examples, the power converter system 100 includes a controller 114 coupled to and configured to operate the charger 104 and the plurality of power converters 110.

[0029] In one example, auxiliary power source 108 includes one or more batteries. As shown, auxiliary power source 108 is coupled to DC bus 106 via auxiliary interface 116. In some examples, auxiliary power source 108 is internal to power converter system 100; however, in other examples, auxiliary power source 108 can be external to power converter system 100.

[0030] In one example, the plurality of power converters 110 includes a first power converter 110a, a second power converter 110b, a third power converter 110c, and a fourth power converter 110d; however, in other examples, the plurality of power converters 110 may include a different number of power converters. Similarly, in one example, the plurality of output terminals 112 includes a first output terminal 112a coupled to the first power converter 110a, a second output terminal 112b coupled to the second power converter 110b, a third output terminal 112c coupled to the third power converter 110c, and a fourth output terminal 112d coupled to the fourth power converter 110d. In other examples, the plurality of output terminals 112 may include a different number of output terminals. For example, the power converter system 100 may have more output terminals than power converters. In such an example, two or more of the plurality of output terminals 112 may be coupled to the same power converter in the plurality of power converters 110 via output terminal switches.

[0031] As shown, input 102 is coupled to an input of a charger 104 and an output of charger 104 is coupled to a DC bus 106. An auxiliary power source 108 is coupled to DC bus 106. Each of a plurality of power converters 110 is coupled to DC bus 106. In one example, each power converter is coupled to DC bus 106 in parallel. In some examples, two or more power converters may be coupled to DC bus 106 in series. As described above, each of the plurality of power converters 110 is coupled to at least one of a plurality of outputs 112.

[0032] In one example, input 102 is configured to receive input alternating current (AC) power from an input power source (e.g., a utility AC power supply). In some examples, input 102 connects to a power outlet on a standard electrical wiring system to receive the input AC power. Charger 104 converts the input AC power to direct current (DC) power and provides the DC power to DC bus 106. In one example, charger 104 can provide DC power to DC bus 106 at a voltage level corresponding to the charging voltage of auxiliary power source 108. For example, the input AC power can have an input voltage level (e.g., 120V), and charger 104 can provide DC power to DC bus 106 at a reduced voltage level (e.g., 46-58V). Similarly, charger 104 can provide DC power to DC bus 106 at a current level corresponding to the charging current of auxiliary power source 108. For example, the input AC power can have an input current level (e.g., 15A), and charger 104 can provide DC power to DC bus 106 at a reduced current level (e.g., 10A). In some examples, charger 104 is configured to adjust the voltage and / or current level of the DC power provided to DC bus 106 based on specific charging parameters of auxiliary power source 108 .

[0033] Auxiliary power source 108 is configured to receive DC power and provide it to DC bus 106. Auxiliary power source 108 can: receive DC power from DC bus 106 for charging in a first state of power converter system 100; and provide power to DC bus 106 to supplement the DC power provided by charger 104 in a second state of power converter system 100. In some examples, auxiliary power source 108 is coupled in series with DC bus 106. For example, a first portion of DC bus 106 can be coupled between charger 104 and an input port of auxiliary power source 108. Similarly, a second portion of DC bus 106 can be coupled between an output port of auxiliary power source 108 and a plurality of power converters 110.

[0034] Each power converter in the plurality of power converters 110 is configured to receive DC power from the DC bus 106 and convert the DC power into output power. In one example, each power converter in the plurality of power converters 110 is configured as a DC / DC converter to provide output DC power. In other examples, each power converter in the plurality of power converters 110 is configured as a DC / AC inverter to provide output AC power. In some examples, a first portion of the plurality of power converters 110 (e.g., the first power converter 110a, the second power converter 110b) can be configured as a DC / DC converter and a second portion of the plurality of power converters 110 (e.g., the third power converter 110c and the fourth power converter 110d) can be configured as an inverter. Thus, the configuration of each power converter can correspond to the desired configuration of the plurality of output terminals 112. For example, each of the plurality of output terminals 112 can have a configuration (e.g., DC or AC) based on the type of load (i.e., device) connected to each output terminal.

[0035] Figure 2 is a flow chart illustrating a method 200 for operating a power converter system according to aspects described herein. In one example, control method 200 corresponds to operation of power converter system 100 in the first and second states described above. In some examples, at least a portion of control method 200 can be performed by controller 114 of power converter system 100.

[0036] At block 202, method 200 begins and power converter system 100 receives input AC power at input 102. At block 204, controller 114 operates charger 104 to convert the input AC power into DC power and provide the DC power to DC bus 106. A plurality of power converters 110 receive DC power from DC bus 106 and controller 114 operates the plurality of power converters 110 to provide output power to a plurality of outputs 112. As described above, each power converter in the plurality of power converters 110 can be configured as a DC / DC converter to provide output DC power or as an inverter to provide output AC power.

[0037] At block 206, the peak output power demands of the plurality of outputs 112 are compared to a peak input power limit of an input power source (e.g., a power grid). The peak power limit of the input power source corresponds to a fixed power limit (e.g., 1200 W) defined by the input voltage and current level (e.g., 120 V, 15 A) provided by the input power source. Thus, the peak power limit of the input source can correspond to a peak voltage limit (e.g., 120 V) and / or a peak current limit (e.g., 15 A). Similarly, the peak output power demand of each output corresponds to the type of load or device coupled to the output. In some examples, the peak output power demand corresponds to a peak output voltage demand and / or a peak output current demand.

[0038] At block 208, in response to the peak output power demand of the plurality of output terminals 112 being less than the peak input power limit, the power converter system 100 operates in a first state. During the first state, the auxiliary power source 108 may receive (or draw) DC power from the DC bus 106 for charging while the DC power is provided to the plurality of power converters 110 to support the peak output power demand. In one example, if the auxiliary power source 108 is fully charged, the auxiliary power source 108 may operate in an idle state (i.e., not receiving or drawing DC power). In some examples, if fully charged, the auxiliary power source 108 may be disconnected from the DC bus 106 (e.g., via a switch). In some examples, while the auxiliary power source 108 is charging (or idle) and the plurality of power converters 110 are providing output power to the plurality of output terminals 112, the power converter system 100 returns to block 206 to continuously monitor the peak output power demand for the peak input power limit.

[0039] At block 210, in response to the peak output power demand of the plurality of output terminals 112 being greater than the peak input power limit, the power converter system 100 operates in a second state. During the second state, the auxiliary power source 108 provides DC power to the DC bus 106 to supplement the DC power provided by the charger 104. In one example, the amount of supplemental DC power provided by the auxiliary power source 108 to the DC bus 106 corresponds to the difference between the peak output power demand and the input power limit. For example, if the input power limit is 1200W and the peak output power demand is 1250W, the auxiliary power source 108 may provide an additional 50W of DC power to supplement the DC power provided by the charger 104. While the auxiliary power source 108 provides supplemental DC power to the DC bus 106 and the plurality of power converters 110 provide output power to the plurality of output terminals 112, the power converter system 100 returns to block 206 to continuously monitor the peak output power demand for the peak input power limit.

[0040] As described above, the peak output power demand corresponds to the peak power level of the devices coupled to the output. Thus, by providing supplemental DC power from auxiliary power source 108 to DC bus 106, power converter system 100 can support devices operating at peak power levels that exceed the input power limit. In some examples, power converter system 100 transitions between the first and second states to support the peak output power demand of multiple outputs 112 while maintaining an average output power demand that is less than the maximum power provided by the input power source.

[0041] In one example, the power converter system 100 is configured to passively transition between the first and second states (i.e., without controller / operator intervention). For example, the auxiliary power source 108 can be configured to automatically draw DC power from the DC bus 106 for charging when the peak output power demand of the plurality of output terminals 112 is less than the peak input power limit. Similarly, when the peak output power demand exceeds the peak input power limit, the auxiliary power source 108 can automatically provide DC power to the DC bus 106.

[0042] Figure 3 A schematic diagram of a power converter system 300 according to aspects described herein is shown. As shown, power converter system 300 includes an input 302, a charger 304, a DC bus 306, a battery 308, a power converter 310, and an output 312. In one example, battery 308 corresponds to auxiliary power source 108 of power converter system 100. Similarly, power converter 310 corresponds to one of multiple power converters 110, and output 312 corresponds to one of multiple outputs 112 of power converter system 100.

[0043] As shown, power converter 310 includes a DC / DC converter 310a and an inverter 310b coupled in series. In one example, DC / DC converter 310a is coupled to DC bus 306 and is configured to boost DC power received from DC bus 306, for example, from a battery charge voltage level to an output voltage level. In other examples, DC / DC converter 310a is configured to provide DC power at a voltage level lower than the battery charge level. Inverter 310b receives DC power from DC / DC converter 310a and converts the DC power into output AC power.

[0044] Battery 308 includes an input port 314 and an output port 316. In one example, input port 314 is coupled to charger 304 via a first portion of DC bus 306, and output port 316 is coupled to power converter 310 via a second portion of DC bus 306. Thus, battery 308 is coupled to DC bus 306 between charger 304 and power converter 310. In some examples, battery 308 includes a single battery module coupled to input port 314 and output port 316; however, in other examples, battery 308 may include multiple battery modules coupled to input port 314 and output port 316.

[0045] As described above, the power converter system 300 is configured so that the battery 308 (i.e., the auxiliary power source 108) can automatically provide and / or receive DC power based on the peak output power demand at the output terminal 312. For example, the power output of the charger 304 is fixed at the peak input power limit (e.g., 1200W). In the first state of the power converter system 300, when the peak output power demand at the output terminal 312 is less than the peak input power limit, the battery 308 can draw DC power from the charger 104 via the input port 314 for charging. Similarly, in the second state of the power converter system 300, when the peak output power demand at the output terminal 312 exceeds the peak input power limit, supplemental DC power is drawn from the battery 308 via the output port 316. Thus, the power converter system 300 can seamlessly transition between the first state and the second state without operator / controller intervention.

[0046] In other examples, active control methods may be used to switch the power converter system 100 between the first and second states. For example, Figure 4 FIG. 4 shows a portion of a power converter system 400 according to aspects described herein. As shown, the power converter system 400 includes an input 402, a charger 404, and a DC bus 406. In one example, the power converter system 400 is similar to Figure 1 4. Power converter system 400 is similar to power converter system 100, except that power converter system 400 includes a power flow control module 412 and a controller 414. Although not shown, power converter system 400 includes a plurality of power converters (i.e., plurality of power converters 110) and a plurality of outputs (i.e., plurality of outputs 112) coupled to DC bus 406. In some examples, controller 414 corresponds to controller 114 of power converter system 100; however, in other examples, controller 414 may be a different / separate controller.

[0047] A power flow control module 412 is coupled to the charger 404, the DC bus 406, and the output of the auxiliary power source 408. Similarly, a controller 414 is coupled to the power flow control module 412, the output of the charger 404, the DC bus 406, and the auxiliary power source 408. In one example, the controller 414 includes current sensors configured to sense current at the output of the charger 404, at the input / output of the auxiliary power source 408, and at the DC bus 406. Thus, the controller 414 can monitor the DC power provided by the charger 404, the DC power provided / drawn at the auxiliary power source 408, and the DC power drawn by the multiple outputs coupled to the DC bus 406 in real time.

[0048] Similar to the example of the power converter system described above, the power converter system 400 can be configured to transition between a first state and a second state based on a fixed peak input power limit (e.g., 1200W). However, in some examples, the controller 414 is configured to dynamically set the peak input power limit based on real-time monitoring of the DC power. For example, one or more variable power sources (e.g., solar panels, wind turbines, etc.) can also be coupled to the input 402, and the controller 414 can adjust (i.e., increase or decrease) the peak input power limit based on the amount of DC power provided by the charger 404 at any given time. In other examples, the controller 414 can adjust the peak input power limit based on additional factors. For example, it may be necessary to limit grid power consumption during certain time periods (e.g., evenings, weekends, etc.) to reduce utility costs. Therefore, the controller 414 can adjust the peak input power limit to reduce grid power consumption accordingly.

[0049] In some examples, based on DC power monitoring and peak input power limits, controller 414 is configured to send commands to power flow control module 412 to operate power converter system 400 in first and second states. For example, when the peak output power demand of the plurality of output terminals is less than the peak input power limit, controller 414 operates power converter system 400 in the first state. In the first state, controller 414 sends commands instructing power flow control module 412 to provide DC power from charger 404 to DC bus 406. Simultaneously, power flow control module 412 is instructed by controller 414 to provide excess DC power from charger 404 to auxiliary power source 408 for charging. Similarly, when the peak output power demand of the plurality of output terminals exceeds the peak input power limit, controller 414 operates power converter system 400 in the second state. In the second state, controller 414 sends commands instructing power flow control module 412 to provide DC power from charger 404 to DC bus 406. Simultaneously, the power flow control module 412 is commanded by the controller 414 to draw supplemental DC power from the auxiliary power source 408 to support the DC power provided by the charger 404 .

[0050] Figure 5 A method 500 of assembling a power converter system according to aspects described herein is shown. In one embodiment, the method 500 may be used, for example, to assemble a Figure 1 A power converter system 100 is provided.

[0051] At step 502, a charger 104 is provided. In one example, the charger 104 is configured to couple to an input power source (e.g., via the input terminal 102) to receive input AC power and convert the input AC power to a first DC power having a first voltage level. At step 504, a DC bus 106 is coupled to the charger 104. In some examples, the DC bus 106 is coupled to the output charger 104 and configured to receive the first DC power having a first voltage level. At step 506, one or more power converters (i.e., a plurality of power converters 110) are coupled to the DC bus 106. In one example, the plurality of power converters 110 are configured to convert the DC power from the DC bus into output power and provide the output power to at least one load (e.g., via the plurality of output terminals 112). At step 508, an auxiliary interface 116 is coupled to the DC bus 106. In some examples, the auxiliary interface 116 is configured to couple to an auxiliary power source 108. In some examples, auxiliary interface 116 is configured to: receive second DC power having a first voltage level from auxiliary power source 108; and provide the second DC power to DC bus 106 to supplement the first DC power provided by charger 104 in response to a voltage or current demand of at least one load exceeding a peak voltage limit or a peak current limit of the input power source.

[0052] As described above, a power converter system configured to increase the peak power capability of a standard electrical system is provided herein. In at least one embodiment, the power converter system includes an auxiliary power source configured to supplement input power provided from an input power source. In one example, the power converter system can provide output power having a peak power level that exceeds the peak power limit of the input power source.

[0053] Having thus described several aspects of at least one embodiment of the present invention, it will be appreciated that various changes, modifications, and improvements will readily occur to those skilled in the art. Such changes, modifications, and improvements are intended to be a part of this disclosure and are intended to fall within the spirit and scope of the present invention. Accordingly, the foregoing description and accompanying drawings are intended to be illustrative only.

Claims

1. A power converter system, characterized in that: The power converter system comprises: an input terminal configured to receive input AC power from an input power source, the input power source having a peak voltage limit and a corresponding peak power limit; at least one output terminal configured to provide output power to at least one load; a charger coupled to the input terminal and configured to convert the input AC power into a first DC power having a first voltage level; a DC bus coupled to the charger and configured to receive the first DC power having the first voltage level; at least one power converter coupled to the DC bus and configured to convert DC power from the DC bus into the output power and provide the output power to the at least one load; and an auxiliary power source coupled to the DC bus and configured to: receiving the first DC power from the DC bus in a first mode of operation in response to a voltage demand of the at least one load being less than the peak voltage limit of the input power source; and in response to the voltage demand of at least one load exceeding the peak voltage limit of the input power source, providing second DC power having the first voltage level to the DC bus in a second mode of operation to supplement the first DC power provided by the charger; The charger is further configured to clamp the first DC power at the peak power limit in both the first and second modes of operation, thereby allowing the power converter system to passively transition between the first and second modes of operation without being affected by a controller or operator.

2. The power converter system according to claim 1, wherein: The power converter system further includes: a power flow control module coupled to the charger, the auxiliary power source, and the DC bus; and The controller is configured as: monitoring the voltage demand of the at least one load relative to the peak voltage limit of the input power source; In response to the voltage demand of the at least one load being less than the peak voltage limit of the input power source, controlling the power flow control module to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source in the first mode of operation; and In response to the voltage demand of the at least one load exceeding the peak voltage limit of the input power source, controlling the power flow control module to draw the second DC power having the first voltage level from the auxiliary power source in the second mode of operation.

3. The power converter system according to claim 2, wherein: The controller is further configured to adjust the peak voltage limit based on at least one of a variability of the input power source, a plurality of utility costs, and a plurality of user preferences.

4. The power converter system according to claim 1, wherein: The at least one power converter includes at least one inverter configured to convert DC power from the DC bus to AC output power.

5. The power converter system according to claim 4, wherein: The voltage level of the AC output power is greater than the peak voltage limit of the input power source.

6. The power converter system according to claim 4, wherein: The at least one power converter includes a DC / DC converter coupled in series with the inverter and configured to convert DC power from the DC bus into DC power having a different voltage level.

7. The power converter system according to claim 1, wherein: The at least one power converter includes at least one DC / DC converter configured to convert DC power from the DC bus to DC output power.

8. The power converter system according to claim 7, wherein: The voltage level of the DC output power is greater than the peak voltage limit of the input power source.

9. The power converter system according to claim 1, wherein: The auxiliary power source includes one or more batteries.

10. A power converter system, characterized in that: The power converter system comprises: an input terminal configured to receive input AC power from an input power source having a peak current limit and a corresponding peak power limit; at least one output terminal configured to provide output power to at least one load; a charger coupled to the input terminal and configured to convert the input AC power into a first DC power having a first voltage level; a DC bus coupled to the charger and configured to receive the first DC power having the first voltage level; at least one power converter coupled to the DC bus and configured to convert DC power from the DC bus into output power and provide the output power to the at least one load; and an auxiliary power source coupled to the DC bus and configured to: receiving the first DC power from the DC bus in a first mode of operation in response to a voltage demand of the at least one load being less than the peak current limit of the input power source; and providing second DC power having the first voltage level to the DC bus in a second mode of operation to supplement the first DC power provided by the charger in response to a current demand of the at least one load exceeding the peak current limit of the input power source; The charger is further configured to clamp the first DC power at the peak power limit in both the first and second modes of operation, thereby allowing the power converter system to passively transition between the first and second modes of operation without being affected by a controller or operator.

11. The power converter system according to claim 10, wherein: The power converter system further includes: a power flow control module coupled to the charger, the auxiliary power source, and the DC bus; and The controller is configured as: monitoring the current demand of the at least one load relative to the peak current limit of the input power source; In response to the current demand of the at least one load being less than the peak current limit of the input power source, controlling the power flow control module to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source in the first mode of operation; and In response to the current demand of the at least one load exceeding the peak current limit of the input power source, controlling the power flow control module to draw the second DC power having the first voltage level from the auxiliary power source in the second mode of operation.

12. The power converter system according to claim 11, wherein: The controller is further configured to adjust the peak current limit based on at least one of a variability of the input power source, a plurality of utility costs, and a plurality of user preferences.

13. The power converter system according to claim 10, wherein: The at least one power converter includes at least one inverter configured to convert DC power from the DC bus to AC output power.

14. The power converter system according to claim 13, wherein: The current level of the AC output power is greater than the peak current limit of the input power source.

15. The power converter system according to claim 14, wherein: The at least one power converter includes a DC / DC converter coupled in series with the inverter and configured to convert DC power from the DC bus into DC power having a different voltage level.

16. The power converter system according to claim 10, wherein: The at least one power converter includes at least one DC / DC converter configured to convert DC power from the DC bus to DC output power.

17. The power converter system according to claim 16, wherein: The current level of the DC output power is greater than the peak current limit of the input power source.

18. A non-transitory computer-readable medium having stored thereon a plurality of sequences of a plurality of computer-executable instructions for operating a power converter system, characterized in that: The plurality of sequences of computer-executable instructions include instructions to instruct at least one processor to control the power converter system to: receiving input AC power at an input terminal from an input power source having a peak voltage limit, a peak current limit, and a corresponding peak power limit; operating a charger coupled to the input terminal to convert the input AC power into first DC power having a first voltage level; providing the first DC power having the first voltage level to a DC bus; operating at least one power converter coupled to the DC bus to convert DC power from the DC bus into output power and provide the output power to at least one load; and providing the first DC power having the first voltage level from the DC bus to an auxiliary power source in a first mode of operation in response to a voltage or current demand of the at least one load being less than the peak voltage limit or the peak current limit of the input power source; and in response to a voltage or current demand of the at least one load exceeding the peak voltage limit or the peak current limit of the input power source, providing second DC power having the first voltage level from the auxiliary power source to the DC bus in a second mode of operation to supplement the first DC power converted by the charger; The plurality of instructions further instruct the at least one processor to operate the charger to clamp the first DC power at the peak power limit in both the first mode and the second mode of operation, thereby allowing the power converter system to passively transition between the first mode of operation and the second mode of operation without being influenced by a controller or operator.

19. The non-transitory computer-readable medium of claim 18, wherein: The plurality of instructions further instruct the at least one processor to control the power converter system to: monitoring the voltage or current demand of the at least one load relative to the peak voltage limit or the peak current limit of the input power source; in response to the voltage or current demand of the at least one load being less than the peak voltage limit or the peak current limit of the input power source, controlling a power flow control module coupled to the charger, the auxiliary power source, and the DC bus to provide the first DC power having the first voltage level from the DC bus to the auxiliary power source in the first mode of operation; and In response to the voltage or current demand of the at least one load exceeding the peak voltage limit or the peak current limit of the input power source, controlling the power flow control module to draw the second DC power having the first voltage level from the auxiliary power source under the second mode of operation.

20. The non-transitory computer-readable medium of claim 19, wherein: The plurality of instructions further instruct the at least one processor to control the power converter system to adjust the peak voltage limit and / or the peak current limit based on at least one of variability of the input power source, utility costs, and user preferences.

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