System for highly efficient GaN-based power conversion with predictive switching control

Abstract

A system for highly efficient power conversion with predictive switching control, including: a power conversion arrangement comprising one or more gallium nitride-based power switches electrically coupled between an electrical input interface for receiving electrical input power and an electrical output interface for delivering converted electrical power to an external load, wherein the gallium nitride-based power switch(es) are configured for operation at high switching frequencies for controlled power conversion; a gate drive unit that is electrically coupled to the control terminals of one or more gallium nitride-based power switches and is configured to generate gate drive signals with controllable timing, voltage amplitude, and transition characteristics to selectively switch the one or more gallium nitride-based power switches on and off; a sensor unit that is electrically coupled to the power conversion unit and configured to acquire electrical parameter data in real time, including at least the input voltage, output voltage, switching current, load current and transient voltage behavior, and further configured to acquire thermal parameter data connected to one or more gallium nitride-based circuit breakers; a processing unit consisting of one or more processors operationally connected to a non-volatile memory that stores predictive switching control logic, wherein the processing unit is operationally connected to the sensor unit and the gate control unit; wherein the processing unit is configured to analyze time-resolved electrical and thermal parameter data to predict impending switching operations and generate predictive switching control signals that adjust at least switching times, dead times, and the gate control behavior prior to the occurrence of corresponding switching events; and wherein the gate control unit is configured to apply the predictive switching control signals to one or more gallium nitride-based power switching devices to reduce switching losses, suppress transient loads, and improve conversion efficiency during operation.

Description

Technical field of the invention

[0001] The present invention relates generally to the field of power electronics and energy conversion systems and in particular to a highly efficient energy conversion system which uses gallium nitride-based switching devices in combination with predictive switching control mechanisms to reduce switching losses, electromagnetic interference and thermal stress in electrical machines, industrial plants and structural energy distribution assemblies. Background of the invention

[0002] Conventional power conversion systems for industrial machinery, electric vehicles, renewable energy generation plants, and distributed energy distribution units are predominantly based on silicon-based switching elements such as IGBTs (Insulated Gate Bipolar Transistors) and MOFS (Metal Oxide Semiconductor Field-Effect Transistors). Although these components are widely used due to their mature technology and cost-effectiveness, they exhibit inherent limitations regarding switching frequency, conduction losses, blocking characteristics, and heat dissipation, which limit the achievable power density and efficiency. With increasing power demands and the growing importance of compact systems, these limitations lead to excessive heat generation, bulky passive components, reduced lifetime, and decreased reliability under dynamic load conditions.

[0003] Recent advances in wide-bandgap semiconductor materials, particularly gallium nitride, have demonstrated superior electrical properties, including higher electron mobility, lower on-resistance, faster switching speeds, and improved breakdown strength. However, the use of gallium nitride-based devices in practical power conversion systems presents new challenges related to fast switching, voltage overshoot, ringing, gate drive sensitivity, and electromagnetic interference. Conventional fixed-frequency and reactive control techniques are insufficient to fully exploit the advantages of gallium nitride devices because they fail to account for real-time changes in load behavior, device temperature, parasitic parameters, and operating conditions.

[0004] Previous solutions attempt to mitigate these problems through passive attenuation techniques such as snubber circuits, ferrite beads, and shielding structures. While such measures can suppress certain transient behaviors, they are generally reactive and lead to additional losses and a higher component count. Furthermore, passive attenuation techniques are usually optimized for fixed operating conditions and can become less effective when the load characteristics or operating environment change. Therefore, designers are often forced to compromise between efficiency, stability, and electromagnetic compatibility.

[0005] The control strategies used in conventional power converter systems further limit the potential advantages of gallium nitride devices. Most existing systems are based on fixed-frequency pulse-width modulation or feedback-based control loops that only react after measured voltage or current deviations occur. While feedback control is essential for maintaining regulation, it inherently introduces delays that become increasingly problematic at high switching frequencies. In fast-switching systems, by the time a deviation is detected and corrective action is initiated, the system may have already experienced significant transient loads or energy losses. This reactive nature of the control limits the ability to optimize switching behavior in real time and leads to suboptimal efficiency under rapidly changing conditions.

[0006] To improve system performance, advanced digital control techniques, including adaptive and model-based control, have been proposed. These approaches utilize mathematical models of the power stage to dynamically adjust control parameters.

[0007] However, many of these implementations are based on idealized or simplified models that do not fully capture the complex interactions between gallium nitride devices, parasitic elements, thermal behavior, and load dynamics. Model inaccuracies can lead to instability or conservative control settings, negating potential efficiency gains. Furthermore, many advanced control solutions require significant computational resources, increasing system costs and power consumption, and making them less suitable for compact or embedded applications.

[0008] Thermal management remains a key challenge in high-efficiency power conversion systems. Although gallium nitride devices generate less heat than silicon devices at the same power output, their high power density leads to local thermal hotspots. Conventional thermal management approaches typically rely on static heat sink designs and fixed cooling strategies that fail to account for fluctuations in power dissipation over time. Consequently, systems are often oversized to accommodate the worst-case thermal load scenarios, resulting in unnecessary dimensions, weight, and material consumption. Furthermore, the lack of integration between thermal behavior and control strategy means that switching decisions are made without considering predicted thermal loads, reducing the overall robustness of the system.

[0009] In machine- and structure-integrated applications such as industrial machinery, electric vehicles, renewable energy systems, and building energy infrastructure, these disadvantages are exacerbated. Power converters in such environments must cope with mechanical vibrations, ambient temperature fluctuations, and highly variable load profiles. Existing solutions often treat the power converter as an isolated component rather than an integral part of the machine or structure. This separation limits the possibilities for shared thermal paths, coordinated control with machine operation, and predictive adaptation to operating conditions, leading to inefficiencies and reduced system optimization.

[0010] Existing power conversion solutions have evolved through incremental improvements in device technology, circuit design, and control methods. However, they remain limited by reactive control paradigms, limited anticipation of switching behavior, and insufficient integration of electrical, thermal, and structural aspects. Gallium nitride-based devices offer significant potential for higher efficiency and power density, but current systems cannot fully realize these benefits due to inadequate handling of high-speed switching dynamics and a lack of predictive control. These shortcomings highlight the need for a fundamentally improved power conversion system capable of anticipating switching operations, proactively managing electrical and thermal loads, and seamlessly integrating into machines and structures to overcome the limitations of existing technologies. Summary of the invention

[0011] The present invention relates to a highly efficient power conversion system that integrates gallium nitride-based switching elements with a predictive switching control architecture. This architecture is designed to predict electrical state transitions and proactively control the switching behavior. The system minimizes switching losses, suppresses voltage and current transients, and improves thermal and electromagnetic performance over a wide operating range. The invention further includes an embodiment in which the system is structurally integrated into a machine or a fixed structure, thus enabling reliable and compact power conversion for applications in industry, transportation, and infrastructure.

[0012] The object of the present invention is a highly efficient power conversion system that overcomes the limitations of conventional silicon-based and reactive power converters by enabling significantly reduced switching losses, improved electrical characteristics, and increased operational reliability under high-frequency conditions. The invention aims to achieve superior efficiency by exploiting the inherent electrical advantages of gallium nitride-based power switches while simultaneously addressing the practical challenges of their high-speed switching behavior.

[0013] A further objective of the invention is to provide a power conversion system with predictive switching control that anticipates electrical state transitions and dynamically adjusts switching parameters before switching operations. By predicting load changes, voltage transitions, and current dynamics, the invention aims to minimize the overlap of voltage and current during the switching process, thereby reducing power loss, mitigating transient loads, and improving overall system efficiency over a wide range of operating conditions.

[0014] A further objective of the invention is to provide a power conversion system that actively suppresses voltage overshoot, ringing, and electromagnetic interference through coordinated control of switching edges and elements for damping transient voltages. The invention aims to reduce dependence on purely passive damping components and reactive damping techniques by enabling proactive control decisions that prevent the generation of harmful transients before they occur.

[0015] A further objective of the invention is the integration of electrical and thermal information into the power conversion process. This allows the system to anticipate thermal stress and adapt its switching behavior to reduce temperature spikes at the transition and thermal loads. This predictive thermal adaptation is intended to extend the service life of gallium nitride-based switching elements and improve long-term reliability without requiring oversized thermal management hardware.

[0016] A further objective of the invention is to provide a compact, high-power-density power conversion system that supports higher switching frequencies without compromising stability or electromagnetic compatibility. By enabling efficient high-frequency operation, the invention contributes to reducing the size and weight of passive components, thus enabling more compact system designs suitable for embedded systems and space-constrained applications.

[0017] A further objective of the invention is to provide a power conversion system that ensures stable and efficient operation even under rapidly changing load conditions and dynamic operating environments. The invention aims to overcome the weaknesses of control strategies with fixed parameters and pure feedback by enabling adaptive, predictive control that remains effective even under unpredictable load behavior and environmental fluctuations.

[0018] A further objective of the invention is to provide an energy conversion system that can be structurally and functionally integrated into machines and fixed structures such as industrial plants, transport platforms, renewable energy generation facilities, and building infrastructure. The invention aims to enable seamless mechanical, thermal, and electrical integration, so that the energy conversion system functions as an embedded functional element rather than an isolated component.

[0019] A further objective of the invention is to provide a power converter that improves system efficiency and reliability by adapting the power conversion behavior to the operating characteristics of the host machine or structure. By enabling predictive adaptation based on machine operating conditions or structural power requirements, the invention supports optimized energy use and reduces the stress on electrical and mechanical components.

[0020] A further objective of the invention is to provide a scalable and adaptable power conversion architecture that can be implemented across a wide range of power levels, voltage classes, and applications without fundamental redesign. The invention aims to support modular expansion and configuration while retaining the core advantages of predictive switching control and gallium nitride-based power conversion.

[0021] Another objective of the invention is to provide a technically robust and industrially applicable power conversion system that improves efficiency, reliability and integration compared to existing solutions, thereby meeting the growing demand for advanced power electronics capable of supporting next-generation machines, energy systems and infrastructures with reduced energy loss and improved operational sustainability. BRIEF DESCRIPTION OF THE IMAGE

[0022] These and other features, aspects and advantages of the present invention will be better understood if the following detailed description is read with reference to the accompanying drawing, in which the same symbols represent the same parts: Fig. Figure 1 shows a block diagram of a system for highly efficient power conversion with predictive switching control.

[0023] Furthermore, those skilled in the art will recognize that the elements in the drawing are simplified and not necessarily drawn to scale. For example, the flowcharts illustrate the process by highlighting the main steps to facilitate understanding of the present disclosure. With regard to the construction of the device, one or more components may be represented in the drawing by conventional symbols. The drawing may show only the specific details relevant to understanding the embodiments of the present disclosure, so as not to clutter the drawing with details that are already apparent to those skilled in the art from the description contained herein. Detailed description of the invention

[0024] To facilitate understanding of the principles of the invention, reference is made below to the embodiment shown in the drawing, which is described using specific terms. It is understood, however, that this does not limit the scope of protection of the invention. Rather, modifications and further developments of the depicted system, as well as further applications of the inventive principles shown therein, are conceivable, insofar as they would normally occur to a person skilled in the art in the field of the invention.

[0025] It will be clear to those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not to be understood as a limitation thereof.

[0026] References to “an aspect”, “another aspect”, or similar phrases in this description mean that a particular feature, structure, or property described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, phrases such as “in one embodiment”, “in another embodiment”, and similar expressions in this description may, but do not necessarily, all refer to the same embodiment.

[0027] The terms "includes," "comprehensive," or similar expressions denote non-exclusive inclusion. Thus, a procedure or method containing a list of steps does not only include those steps but may also include further steps not explicitly listed or inherent in the procedure or method. Likewise, the statement "includes..." for one or more devices, subsystems, elements, structures, or components, without further limitations, does not preclude the existence of other devices, subsystems, elements, structures, or components.

[0028] Unless otherwise defined, all technical and scientific terms used herein have the same meanings generally known to those skilled in the art in the field to which this invention belongs. The systems, methods, and examples described herein serve only for illustration and are not to be understood as limiting.

[0029] Embodiments of the present disclosure are described in detail below with reference to the attached drawing.

[0030] Fig.Figure 1 shows a block diagram of a high-efficiency power conversion system with predictive switching control. The system 100 comprises: a power conversion unit (102) with one or more gallium nitride-based power switches electrically coupled between an input interface for receiving electrical input power and an output interface for delivering the converted electrical power to an external load. The gallium nitride-based power switches are designed for operation at high switching frequencies for controlled power conversion. The unit further comprises a gate drive unit (104) electrically connected to the control terminals of the gallium nitride-based power switches, which generates gate drive signals with controllable time, voltage amplitude, and transition characteristics to selectively switch the gallium nitride-based power switches on and off; and a sensor unit (106).which is electrically coupled to the power conversion unit and configured to acquire electrical parameter data in real time, including at least the input voltage, output voltage, switching current, load current, and transient voltage behavior, and which is further configured to acquire thermal parameter data connected to one or more gallium nitride-based power switches; a processing unit (108) with one or more processors operationally connected to a non-volatile memory storing predictive switching control logic (108a), wherein the processing unit is operationally connected to the sensor unit and the gate drive unit; wherein the processing unit is configured to analyze time-resolved electrical and thermal parameter data to predict impending switching operations and generate predictive switching control signals,which at least adjust the switching times, dead times and the gate control behavior before the occurrence of corresponding switching events; and wherein the gate control unit is configured to apply the predictive switching control signals to one or more gallium nitride-based power switching devices to reduce switching losses, suppress transient loads and improve conversion efficiency during operation.

[0031] In one embodiment, the sensor unit (106) comprises a plurality of voltage and current sensors arranged at electrically distinct locations within the power conversion arrangement. The sensor elements are arranged to detect both steady-state and transient electrical behaviors associated with individual switching cycles of the one or more gallium nitride-based circuit breakers.

[0032] In one embodiment, the sensor unit (106) further comprises temperature sensor elements which are thermally coupled to corresponding gallium nitride-based power switches.

[0033] The temperature sensor elements are configured to generate temperature data that are representative of the junction temperature changes occurring during successive switching cycles.

[0034] In one embodiment, the predictive switching control logic (108a) executed by the processing unit is configured to generate future switching state predictions based on historical switching cycle data, current load behavior and detected trends in electrical and thermal parameters, so that switching control adjustments can be determined before initiating a corresponding switching operation.

[0035] In one embodiment, the processing unit (108) is configured to dynamically adjust the switching frequency and duty cycles to predicted load changes, so that the efficiency is maintained even under rapidly changing load conditions without the need for correction by reactive current feedback after the occurrence of voltage or current deviations.

[0036] In one embodiment, the gate drive unit (104) comprises electrically isolated drive stages and a circuit for adjusting the drive strength. The drive strength adjustment circuit is controlled by the processing unit to modify the gate drive transition rates in advance of the predicted transient formation, thereby reducing voltage overshoot and ringing.

[0037] In an embodiment which further includes a transient suppression unit electrically coupled to the power conversion unit, the transient suppression unit is selectively activated in coordination with predictive switching control signals generated by the processing unit in order to suppress expected transient phenomena during the switching operations.

[0038] In one embodiment, the processing unit (108) is further configured to perform a predictive thermal assessment by correlating the predicted switching behavior with the predicted thermal response of one or more gallium nitride-based circuit breakers and modifying the switching parameters in advance to limit the predicted increase in junction temperature.

[0039] In one embodiment, the power conversion unit is mounted on a thermally conductive substrate and enclosed in a structurally rigid housing configured to provide mechanical support and heat dissipation. The housing is designed for integration into a machine or a fixed structural installation.

[0040] In one embodiment, the housing is designed for direct mounting in an industrial machine, wherein the electrical input interface and the electrical output interface are arranged so that the system can be electrically coupled to the busbars of the machine and the electrical loads operated by the machine.

[0041] The processing unit executes the predictive switching control logic stored in non-volatile memory. First, it creates a time-based representation of the recent switching behavior by dividing the incoming parameter data into successive switching intervals. For each switching interval, the processing unit determines characteristic values ​​such as the upstream voltage, upstream current, switching duration, observed voltage overshoot, and the instantaneous temperature rise associated with the switching operation. These characteristic values ​​are stored as a continuous history in memory and reflect the current operating behavior of the power conversion unit.

[0042] Using historical data, the processing unit performs a trend analysis to identify patterns in load fluctuations, current rise, voltage dynamics, and thermal behavior. The algorithm evaluates correlations between the rate of change of the load current and the observed switching load, as well as between the switching frequency and the temperature rise. Based on these correlations, the processing unit generates predictive parameters for the switching conditions of future switching intervals. These predictive parameters include the expected current at the next switching event, the predicted voltage transition characteristics, and the anticipated thermal effects of a switching operation under the current operating conditions.

[0043] Before a switching operation begins, the processing unit determines optimal switching control settings based on the predicted switching parameters. The algorithm calculates adapted switching times by advancing or delaying the switching edge relative to a nominal time reference value to reduce the overlap of voltage and current during the transition. Furthermore, the algorithm determines a suitable dead-time interval to prevent the simultaneous conduction of complementary switching elements. In doing so, it considers the predicted current direction and magnitude and does not rely solely on fixed dead-time settings.

[0044] In addition to adjusting the switching timing, the processing unit determines the gate drive behavior by selecting the appropriate transition characteristics for the predicted switching conditions. If the algorithm predicts a high-current or high-voltage transition likely to result in overshoot or ringing, the processing unit generates control signals that instruct the gate drive unit to reduce the transition speed before the switching operation. Conversely, if the predicted conditions indicate a low risk of transients, the algorithm enables faster gate transitions to minimize switching losses. These gate drive adjustments are made proactively before the switching operation, rather than reactively in response to detected transients.

[0045] By predicting the thermal impact of expected switching operations based on current temperature trends and the forecasted switching energy, the processing unit identifies conditions under which the junction temperature is expected to exceed predefined thermal thresholds. The algorithm then proactively adjusts the switching frequency, duty cycle, or gate drive behavior to reduce the predicted temperature rise. This proactive thermal adjustment allows the system to limit thermal stress without interrupting power conversion or resorting to thermal shutdown mechanisms.

[0046] During each switching operation, the transient suppression unit works in coordination with the predictive switching control logic. The processing unit activates or modifies the transient suppression, for example, through controlled damping or energy absorption, based on the predicted transient strength. Because the transient suppression unit is activated preventively before switching operations and not only after the detection of excessive voltage or current deviations, the system achieves improved suppression of overshoot and electromagnetic interference while simultaneously reducing energy loss.

[0047] After each switching operation, the processing unit compares the predicted switching behavior with the measured values ​​acquired by the sensor unit. The algorithm evaluates deviations between predicted and actual voltage overshoot, switching duration, and temperature rise. These deviations are used to update internal prediction parameters stored in memory, thus refining future predictions. This continuous update process allows the predictive switching control logic to adapt to changes in device characteristics, aging effects, environmental conditions, and load profiles without requiring recalibration or system downtime.

[0048] When integrated into a machine, the system coordinates predictive switching control with the machine's operating states. The processing unit receives information about the machine's load requirements and operating transitions via the electrical input interface or auxiliary signals. This allows the algorithm to anticipate changes in power demand during acceleration, deceleration, or load switching. The switching control is thus adapted to the machine's behavior, reducing the electrical load during mechanically induced load changes.

[0049] When implemented in a structurally integrated configuration, such as a power distribution cabinet or a renewable energy generation plant, the algorithm adapts its predictive switching behavior to grid conditions, supply fluctuations, and aggregated load changes. By anticipating these fluctuations, the system ensures stable efficiency and reduced electromagnetic interference even under dynamic power demands from the structure.

[0050] The described system comprises a power conversion unit with one or more gallium nitride-based power switches electrically coupled between an input power source and an output load. The gallium nitride-based power switches are designed for high-frequency switching operations to convert electrical energy from one form to another. This includes, among other things, AC-to-DC conversion, DC-to-AC inversion, voltage step-up conversion, and voltage step-down conversion. Each gallium nitride-based power switch is mounted on a thermally conductive substrate and electrically connected via low-inductance connections to minimize parasitic effects during rapid switching operations.

[0051] The system further includes a gate drive assembly coupled to the gallium nitride-based power switches. This drive assembly is configured to apply controlled gate voltage waveforms to turn the switches on and off. The gate drive assembly incorporates isolation elements, level shifters, and adaptive drive strength control to ensure stable switching behavior under varying electrical conditions. Gate voltage timing, amplitude, and slew rate are selectively adjustable depending on the predictive control outputs generated by the system.

[0052] A sensor array is coupled to the power conversion unit and continuously monitors electrical and thermal parameters such as input voltage, output voltage, load current, switching current, junction temperature, and transient voltage characteristics. The sensor array provides time-resolved parameter data to a processing unit with one or more processors connected to non-volatile memory. This memory stores predictive control logic and operating models.

[0053] The processing unit is configured to execute predictive switching control logic. This logic analyzes historical and real-time parameter data to predict upcoming switching operations and electrical state transitions. The predictive switching control logic utilizes the temporal correlation of load behavior, switching cycle history, and thermal response characteristics to determine optimal switching times, dead times, and gate drive profiles for subsequent switching cycles. By predicting switching operations, the system dynamically adjusts the switching frequency, duty cycle, gate timing, and dead time to minimize the overlap of voltage and current waveforms during switching operations.

[0054] The system also includes a transient suppression device electrically coupled to the power converter assembly. This device suppresses voltage overshoot, overshoot, and electromagnetic interference that occur during high-speed switching. The predictive switching control works in conjunction with the transient suppression device by modulating the switching edge rate and proactively controlling the activation of the damping element, rather than reacting only after transients have occurred.

[0055] Thermal management is integrated into the system through a thermally conductive housing and a heat dissipation structure. This structure is designed to dissipate heat from the gallium nitride-based power switches and associated circuitry. The predictive switching control logic also incorporates thermal forecasting based on junction temperature trends and load profiles. This proactively reduces the switching load during predicted temperature peaks, extending component lifetime and improving system reliability.

[0056] In one embodiment, the system is implemented as a device integrated into a machine. This device comprises a housing for direct mounting in an industrial machine, an electric motor, a robot system, or a transport platform. The housing contains the power converter unit, the processing unit, the sensor unit, and the thermal management system as an integrated unit. Electrical interfaces connect the device to the machine's busbars, control networks, and load connections. Thus, the device serves as an embedded power converter unit that provides regulated electrical energy for the machine's subsystems.

[0057] In another embodiment, the system is implemented as a device integrated into a fixed structure, for example, in a power distribution cabinet, a renewable energy generation plant, a building infrastructure system, or a charging station. This structural integration ensures mechanical stability, environmental protection, and heat dissipation to structural elements such as mounting frames or heat sinks. The predictive switching control system enables the device to adapt to fluctuating grid conditions, load changes, and ambient temperature variations, while simultaneously ensuring high efficiency and low electromagnetic interference.

[0058] By combining gallium nitride-based circuit breakers with predictive switching control, the presented system achieves significantly higher power density, higher efficiency, and improved operational stability compared to conventional power converters. The predictive control logic enables the optimization of switching behavior before adverse conditions occur. This reduces energy losses, minimizes component stress, and ensures reliable operation even under demanding machine and plant conditions.

[0059] The power converter assembly, gate driver, sensor unit, processing unit, and electrical inputs and outputs are each integrated as hardware components within a single power converter. The power converter assembly consists of gallium nitride-based semiconductor switching elements mounted on a power substrate and electrically interconnected via conductor tracks, bus bars, and passive power components to transfer and regulate electrical energy between the inputs and outputs. The gate driver is implemented as a dedicated electronic circuit comprising driver transistors, isolation elements, a clock generator, and a voltage regulator. It is connected via conductor tracks to the control terminals of the switching elements to provide precise gate drive signals.The sensor unit comprises discrete electrical and thermal sensing elements, analog input circuits, and signal lines connected to the power converter assembly to directly measure voltages, currents, and temperatures during operation. The processing unit includes one or more semiconductor processing devices and non-transient memory elements mounted on a printed circuit board and interconnected via data and control buses. This enables real-time acquisition and processing of the measurement parameters. Electrical coupling between the processing unit and the gate drive unit is achieved via physical signal lines and registers that transmit predictive control signals.

[0060] The drawing and the preceding description illustrate embodiments. Those skilled in the art will recognize that one or more of the described elements can be combined to form a single functional element. Alternatively, certain elements can be divided into several functional elements. Elements of one embodiment can be added to another. For example, the process flows described here can be modified and are not limited to the manner described herein. Furthermore, the actions of a flowchart need not be performed in the sequence shown; nor do all actions necessarily need to be carried out. Actions that do not depend on other actions can be performed in parallel with the other actions. The scope of protection of the embodiments is in no way limited by these specific examples. Numerous variations, whether explicitly stated in the description or not, such as...Differences in structure, dimensions, and materials are possible. The scope of protection of the embodiments is at least as comprehensive as described by the following claims.

[0061] The advantages, other benefits, and problem solutions have been described above with reference to specific embodiments. However, the advantages, benefits, problem solutions, and any components that can effect or enhance an advantage, benefit, or solution are not to be construed as critical, necessary, or essential features or components of the claims. REFERENCES 100 A system for highly efficient energy conversion with predictive switching control. 102 Power conversion module 104 Gate drive unit 106 Sensor unit 108 processing units 108a Predictive switching control logic

Claims

[1] A system for highly efficient power conversion with predictive switching control, comprising: a power conversion arrangement comprising one or more gallium nitride-based power switches electrically coupled between an electrical input interface for receiving electrical input power and an electrical output interface for delivering converted electrical power to an external load, wherein the gallium nitride-based power switch(es) are configured for operation at high switching frequencies for controlled power conversion; a gate drive unit that is electrically coupled to the control terminals of one or more gallium nitride-based power switches and is configured to generate gate drive signals with controllable timing, voltage amplitude, and transition characteristics to selectively switch the one or more gallium nitride-based power switches on and off; a sensor unit that is electrically coupled to the power conversion unit and configured to acquire electrical parameter data in real time, including at least the input voltage, output voltage, switching current, load current and transient voltage behavior, and further configured to acquire thermal parameter data connected to one or more gallium nitride-based circuit breakers; a processing unit consisting of one or more processors operationally connected to a non-volatile memory that stores predictive switching control logic, wherein the processing unit is operationally connected to the sensor unit and the gate control unit; wherein the processing unit is configured to analyze time-resolved electrical and thermal parameter data to predict impending switching operations and generate predictive switching control signals that adjust at least switching times, dead times, and the gate control behavior prior to the occurrence of corresponding switching events; and wherein the gate control unit is configured to apply the predictive switching control signals to one or more gallium nitride-based power switching devices to reduce switching losses, suppress transient loads, and improve conversion efficiency during operation. [2] System according to claim 1, wherein the sensor unit comprises a plurality of voltage and current sensors arranged at electrically distinct locations within the power conversion arrangement. The sensor elements are arranged to detect both steady-state and transient electrical behaviors associated with individual switching cycles of one or more gallium nitride-based power switches. [3] System according to claim 1, wherein the sensor unit further comprises temperature sensor elements which are thermally coupled to corresponding gallium nitride-based power switches, wherein the temperature sensor elements are configured to generate temperature data which are representative of the junction temperature changes occurring during successive switching cycles. [4] System according to claim 1, wherein the predictive switching control logic executed by the processing unit is configured to generate future switching state predictions based on historical switching cycle data, current load behavior and detected trends in electrical and thermal parameters, so that switching control adjustments are determined before initiating a corresponding switching operation. [5] System according to claim 1, wherein the processing unit is configured to dynamically adjust the switching frequency and duty cycles to predicted load changes, so that the efficiency is maintained even under rapidly changing load conditions without the need for correction by reactive current feedback after the occurrence of voltage or current deviations. [6] System according to claim 1, wherein the gate drive unit comprises electrically isolated drive stages and an adjustable drive circuit, wherein the adjustable drive circuit is controlled by the processing unit to modify the gate drive transition rates in advance of the predicted transient formation in order to reduce voltage overshoot and ringing. [7] The system according to claim 1 further comprises a transient suppression unit electrically coupled to the power conversion unit, wherein the transient suppression unit is selectively activated in coordination with predictive switching control signals generated by the processing unit in order to suppress expected transient phenomena during the switching operations. [8] System according to claim 1, wherein the power conversion unit is physically mounted on a thermally conductive substrate and enclosed in a structurally rigid housing configured to provide mechanical support and heat dissipation, the housing being suitable for integration into a machine or a fixed structural installation. [9] System according to claim 8, wherein the housing is designed for direct mounting in an industrial machine and the electrical input interface and the electrical output interface are arranged such that the system can be electrically coupled to the busbars of the machine and the electrical loads operated by the machine.

Images