Sustainable universal power conversion system

Abstract

The present invention relates to a power-electronics power conversion system (10), suitable for forming part of an energy station and comprising at least two multiport conversion modules, a first conversion module (1A) and a second conversion module (1B), characterized in that, in the power conversion system (10), each conversion module (1A, 1b,...) is connected in series and / or in parallel with one or more other conversion modules (1A, 1B,...), the module controllers (6) of the conversion modules (1A, 1B,...) communicating with one another via a link (12) in order to exchange system management data.

Description

SUSTAINABLE UNIVERSAL ENERGY CONVERSION SYSTEM Object of the invention

[0001] The present invention relates to the development and design of energy conversion systems, in particular: - backup and storage for various purposes, such as interconnecting renewable sources, electric vehicles, or other loads / sources (e.g., fuel cell, hydrolyzer, micro-turbine), - such as precision power supplies for magnets for research and medicine, or power supplies for generating electric arcs, etc., which are suitable for rack-mountable design, modular, scalable, easy to maintain and robust. Technological background and state of the art

[0002] In the current context of the deployment of renewable energies and the foreseeable electrification of many energy uses, the needs for interconnection and electrical conversion are increasingly numerous and varied.

[0003] Thus, the battery energy storage systems (BESS) market is experiencing strong growth to meet the challenges posed by the integration of renewable energies into electrical grids. In this context, the introduction of flexibility in consumption management is crucial for balancing and stabilizing electrical grids, while power electronic converters and their digital control are essential to this energy transition.

[0004] The aforementioned electrical interconnection and conversion needs include, in particular, connection to the public grid or a microgrid using AC and / or DC technology, renewable energy production equipment (solar, wind), battery storage, charging stations for electric vehicles, and uninterruptible power supplies (UPS) for critical loads. Each of these devices is distinguished by specific physical parameters: voltage, current, power curve, response time, etc. (see Figure 1).

[0005] It is known that multiple cascading conversions in energy flows degrade efficiency (see Figure 1). There are numerous conversion providers, each with their own specific technology and generally incompatible with each other, not to mention the software involved. Installation and maintenance are complex without the possibility of prefabrication. Furthermore, in most solutions offered on the market, the grid remains the common element through which all these energy flows are transferred. Consequently, the microgrid is grid-dependent. In the event of a failure, switching to backup mode, even if possible, requires at least a brief service interruption, which is problematic for sensitive loads.

[0006] US2023 / 0327574A1 discloses a modular multilevel converter and a method for synchronizing the outputs of the converter's submodules. The modular multilevel converter comprises submodules connected in parallel, each generating an output. The modular multilevel converter also includes a controller communicatively coupled to the submodules. The controller manages the flow of one or more synchronization signals between the plurality of submodules, such that each submodule simultaneously receives synchronization signals in opposite directions, thereby controlling the synchronization of the outputs generated by the submodules.

[0007] Document WO16165718A1 discloses a wind turbine converter system comprising controllers for inverters and a distributed error-handling system, as well as an associated control method. The inverter controllers are connected via a communication bus to using one or more communication rings. The communication bus allows a control word to circulate between inverter controllers. When an inverter controller detects a failure in an associated inverter, the inverter controller produces a control word indicating the detected failure. This control word, indicating the detected failure, circulates to all other inverter controllers on the communication bus, and the inverter controllers perform a response action to the given failure.

[0008] Document AT501422B1 describes an inverter system for supplying power to a three-phase network, regardless of sunlight. The greater the sunlight, the more energy or power is required to supply the three-phase network. Therefore, individual inverters should be combined according to requirements and connected in parallel. For this purpose, one inverter is designated by a central control unit, according to specific criteria, as the master inverter, and all other inverters as slave inverters. The single-phase inverters are also grouped into three sets, one set per phase, to prevent load imbalances between phases.

[0009] US patent 10720775B2 discloses a conversion module for converting electrical power by means of a conversion circuit comprising at least one solid-state switch using time-controlled power electronics. The conversion module includes a housing, a first intermediate circuit connection terminal, and a capacitor located within the housing and connected to the first intermediate circuit connection terminal and to the conversion circuit. This capacitor serves to stabilize a DC voltage applied to the first intermediate circuit connection terminal. The conversion module includes a second intermediate circuit connection terminal connected to the capacitor and the first intermediate circuit connection terminal.The first intermediate circuit connection terminal and the second intermediate circuit connection terminal are intended to be connected to the intermediate circuit connection terminals of other conversion modules to convert electrical power. An inverter can be formed by at least two of these. conversion modules which are connected to each other by respectively one of their intermediate circuit connection terminals.

[0010] US Patent 10658844B2 discloses a modular power conversion and power electronics system that enables any power-generating device or entity to connect to any electrical load or network, including, but not limited to, the conversion of electricity between one or more low-level producers such as a diesel or gas generator, a Stirling engine, a wind turbine, or a photovoltaic array, and a consumer such as a commercial or residential building, either directly or via the grid. The modular power conversion system, including hardware and software power electronics, designed as a modular power stage encompassing various power-generating entities, transmission systems, consumption and loads, and energy storage, is also disclosed.

[0011] US2006 / 0120001 A1 discloses a modular power converter that readily adapts to a wide variety of applications by separating the substantially constant power conversion functions from the largely application-specific power converter components. A central power conversion module is provided, which includes the conversion functions and thermal systems of a typical power converter. An output connector is provided for coupling the central module to an application-specific module that can contain application-specific components such as magnets, filters, contactors, relays, current sensors, etc. An easily reconfigurable cabinet is included and can be readily adapted to particular applications.

[0012] Document EP3333005B1 discloses power electronics for charging at least one electric vehicle, the power electronics comprising at least two modules, each with at least one pair of terminals with DC output, at least one rectifier, at least one AC input, at least one DC voltage intermediate circuit, and a number of switching elements, the switching elements being arranged on and / or between the DC outputs of at least two modules such that between the at least two modules, at least one series circuit configuration and one parallel circuit configuration can be dynamically set as selected by appropriate switching purposes of the switching elements.

[0013] Document CN103904912B discloses a power electronics block comprising a housing, a power module mounted in the housing, a controller mounted in the housing and coupled to the power module, a capacitor coupled to the power module and mounted in the housing, an AC bus bar mounted in the housing, and a DC bus bar coupling the capacitor to the power module and mounted in the housing.

[0014] US8848401 B2 discloses an electronic power converter for use in high-voltage direct current transmission with reactive power compensation, which converter comprises at least one conversion branch. Each conversion branch includes a first and a second DC terminal for in-service connection to a DC network, and an AC terminal for in-service connection to an AC network. Each conversion branch defines a first and a second branch section that are connected in series between the AC terminal and one of the respective first and second DC terminals. Each branch section includes a string converter that is connected in series with at least one primary switching element.Each string converter comprises a plurality of modules connected in series, and each module includes at least one secondary switching element connected to at least one energy storage device. The primary switching element(s), on each branch section of a respective conversion branch, selectively defines a circulation path that carries a direct current to regulate the energy level of at least one energy storage device in the respective string converter.

[0015] US patent 9516761 B2 discloses a method for encapsulating electronic component panels, such as current converters, which reduces the wasted surface area of ​​a circuit board. Printed. After encapsulation, the panel, which may contain multiple components, can be cut into one or more separate parts. The mold can be used to form part of the finished product, for example, to obtain heat sink fins or a surface-mount solderable surface. Interconnect elements located along the edges of individual circuits are exposed during the separation process, forming electrical connections to the components without wasting any usable printed circuit board area.The molds can incorporate various internal features, such as alignment elements that precisely position the printed circuit board within the mold cavity, locking contours that ensure the structural integrity of the separated module, contours that match the shapes and sizes of components, improving heat dissipation from internal components and reducing the volume of encapsulating agent required, clearance channels that provide spacing recommended by safety agencies, and recesses for interconnections. After encapsulation, large cutouts can be made in the molds, reducing thermal stress and decreasing the thickness of the material to be cut during subsequent separation.The external mold components can feature various heat sink fin configurations, flat surfaces for surface mounting or welding, and other features. Rough mold panels can be machined to provide some or all of the aforementioned features in an on-demand manufacturing system. Connection adapters can be installed to use the modules in vertical or horizontal mounting positions, with various welding options including connector welding, through-hole mounting, or surface mounting. Interconnects can be plated to create a connectorized module that can be inserted into a corresponding connector. Heat sink panels can be replaced with reusable plates. Alternatively, the panel can be encapsulated in a reusable mold and then separated after curing.

[0016] Document US10381924B2 relates to an electrical current conversion device that includes a converter having a circuit The control circuit consists of a regulator and a switching network. The regulator circuit has magnetic storage elements and switches connected to the magnetic storage elements that can be controlled to switch between different switching configurations. The regulator circuit maintains an average direct current through a magnetic storage element. The switching network comprises charge storage elements connected to switches that can be controlled to switch between different switching configurations. In one configuration, the switches form an arrangement of charge storage elements in which at least one charge storage element is charged using the magnetic storage element via the network's input or output port.In another configuration, the switches form an arrangement of charge storage elements in which an element discharges using a magnetic storage element, through an input port or an output port of the switching network.

[0017] US Patent 2013 / 099565 A1 relates to a modular power conversion system and power electronics that enable any power-generating device or entity to connect to any electrical load or network, including, but not limited to, the conversion of electricity between one or more low-level producers such as a diesel or gas generator, a Stirling engine, a wind turbine, or a photovoltaic array, and a consumer such as a commercial or residential building, either directly or via the grid. The invention also relates to a modular power conversion system comprising hardware and software power electronics designed as a modular power stage aggregating various power-generating entities, transmission systems, consumption and loads, and energy storage.

[0018] Document CA 2 349 058 A1 relates to a power supply module comprising a plurality of power supply modules. One of the power supply units is designated as the master power supply unit. The other power supply units are treated as expansion power supply units. The power supply modules can be connected in parallel on a DIN rail so that the master power supply unit can provide a voltage External alternative to expansion power supplies. When a desired power supply capacity exceeds the power supply capacity of the master power supply unit, an expansion power supply unit is connected in parallel with the master power supply unit to increase the power supply capacity. Objectives of the invention

[0019] The present invention aims to develop an open, scalable energy conversion and flow management platform offering flexibility and performance optimization to meet multiple applications and different markets by accelerating the development process and time-to-market.

[0020] The invention aims particularly at developing a microgrid solution for converting and managing installed BTM (Behind The Meter) energy flows, with energy generation and storage on the consumer side, such as residential solar, batteries, diesel generator, offering a modular and flexible approach to meet various electrical needs and environments and using a modular architecture, with a view to improving energy efficiency, reducing costs and offering a versatile and adaptable solution to the different situations that may be encountered in a microgrid structure.

[0021] A main objective of the invention is to enable users of the 10kW-500kW / 2MW (BTM) range to have total control over their consumption and production, regardless of the type of load or source, in a context where the availability of the electrical network is not guaranteed. Main characteristic elements of the invention

[0022] One aspect of the present invention relates to a power electronics power conversion system comprising at least two multiport conversion modules, a first conversion module and a second conversion module, according to claim 1.

[0023] Preferred embodiments of the invention are presented in the dependent claims. Brief description of the figures

[0024] Figure 1 schematically represents a typical microgrid (BTM) solution, with an example of efficiency degradation on energy flow.

[0025] Figure 2 represents an example of two multiport modules assembled from "elements" according to the present invention.

[0026] Figure 3 represents an example of a rackable and modular system in an independent micro-network structure, according to the invention.

[0027] Figure 4 schematically represents the "elements" in AC and DC (by analogy with the Lego® brick system).

[0028] Figure 5 schematically represents the creation of rack-mountable multiport modules based on the aforementioned elements.

[0029] Figure 6 schematically represents the creation of a system by stacking rack-mountable modules.

[0030] Figure 7 shows the schematic representation of the multilevel system / module / converter control in the case of a modular platform with parallelized modules. Detailed description of the invention

[0031] The project according to the present invention, based on expertise in the design of rack-mountable and modular, scalable, easy-to-maintain and robust energy conversion systems, aims to develop a power conversion platform comprising Lego® brick-type units or sub-assemblies, also rack-mountable and modular.

[0032] In the spirit of the invention, modularity refers to the series or parallel connection of rack-mountable power converters. This will be explained below. below is the vision of the inventors regarding the concept of easy racking according to the present invention.

[0033] In this application, a Lego® brick-type unit or subset is defined as a unit or subset that can be fitted into another unit or subset of the same type, for example, but not exclusively, by means of corresponding protrusions and cavities; any other means of quick attachment between two units is envisaged according to the present invention. The analogy can, of course, be extended beyond the mechanical domain, such as the concept of linking bricks of different types (e.g., DC / DC and DC / AC) via common connections (e.g., a common DC connection for power, a controller module for communication).

[0034] The prior art multiport (“hybrid”) power converter module is transformed and adopted according to the invention as a modular assembly 1 subdivided into two, three, or four elementary converter boards 2 (see Figure 2). This approach makes it possible to build various hybrid modules with a limited number of “elements,” thus reducing development effort and achieving economies of scale. The platform is therefore scalable. According to the invention, advantageously, a maximum of at least 6 elements per module and a maximum of at least 100 modules could be achieved.

[0035] The architecture envisaged according to the invention maintains the principle of a rackable and modular structure (see figure 3). It will be noted that the modules are heterogeneous (in figure 3, the two outer modules differ in the nature and number of their sub-modules).

[0036] The objectives include improved performance (~99%), a high power density (in W / cm²) 3 ), wide operating voltage ranges, bidirectional conversion capability, and multiple operating modes. Energy flows are exchanged within the module, directly between the primary conversion stages, reducing the number of conversions and associated losses, which significantly improves overall efficiency (see Figure 2). Thus, each transfer takes place over two stages instead of four (98% efficiency per transfer or converter). For a generation / storage / use cycle, we have a total efficiency of 96% instead of 92% according to the state of the art.

[0037] The system is designed to operate in an integrated manner preferably without the use of multiple suppliers and / or complex software, and paves the way for prefabricated solutions without the need for qualified personnel for on-site installation.

[0038] Energy transfers thus occur without going through the grid. (General), making the created micronetwork completely independent. This allows for instantaneous switching to backup mode, without interruption. The installed power seen by the network is reduced to that of the connected floor (see Figure 2), unlike traditional solutions where the network sees the sum of the equipment power (see Figure 1). This difference is significant and essential for the distribution network operator (DNO) in terms of potential disruptions.

[0039] According to a particular form of execution, performance optimization and certain use cases require operation in a closed environment, without forced ventilation.

[0040] Advantageously, the proposed modular architecture will be extremely flexible. While it is relatively easy to guarantee the operation of each basic element according to its technical specifications, it is very difficult to predict the system's stability for all possible combinations of assemblies, operating modes, and environments. This is why digital models are developed from the outset of the project, using a structural and systematic approach.

[0041] Key steps include: - develop relevant models for the modules; - create a methodology for modeling and identifying the parameters of the external systems and multiple electrical environments to which the modules will be connected. Often, "black box" type models will be necessary; - propose suitable control algorithms for the modules created.

[0042] Advantageously, the architecture will be transparent to the user, and implementation should be achievable by unskilled personnel. Application scenarios, electrical environments, and their evolution are difficult to predict. Simulation tools will be adapted to create wizards that facilitate on-site parameterization and optimization. Description of preferred embodiments of the invention Lexical preamble

[0043] This glossary aims to clarify and define specific terms that will be used to describe the project's elements. Understanding these terms is essential to grasping the nuances and complexities of modern power conversion systems, which play a crucial role in various applications ranging from data centers to microgrids.

[0044] Port 3: Any usable connection on a converter is called a "port." Most often, a converter is connected to a source and a load: this is then a "2-port" converter. "3-port" converters are also common. Examples of 2-port converters: rectifier, EV charger, inverter, PV inverter, grid-tie inverter, unidirectional or bidirectional DC / DC converter. Examples of 3-port converters: backup power supply, telecom inverter, hybrid PV inverter, hybrid grid-tie inverter, DC & AC microgrid applied to critical loads.

[0045] Element 2: A "2-port" converter consists of two primary stages: an input stage and an output stage. These are connected by a temporary, non-directly usable energy reserve. An "element" will be defined as a simple, bidirectional, autonomous, and intelligent conversion stage with at least two ports: an external port and an internal port. One of these ports (the internal port) provides a voltage designated as pseudo-DC (see below). An element can have, for example, up to four ports (e.g., DC, L1, L2, L3).

[0046] Module 1: In accordance with the literature and vernacular specific to power electronics, a module is a A converter transforms the energy from a source into usable electrical energy. This can be a voltage or current conversion. It typically includes other functions such as filtering, current adjustment, flow redirection, etc. It is typically software-controlled. We will mainly be discussing rack-mountable and parallelizable modules. In the spirit of this invention, a module will consist of several elements (up to 6, as already mentioned). The elements, and in particular the ports, can be combined in parallel, series, or series / parallel configurations.

[0047] Isolation: We speak of galvanic isolation between two electrical or electronic circuits, the fact that there is no conductive connection such as an electrical wire, metal chassis, etc., between these two circuits. It will be represented by a double line in diagrams, as is customary.

[0048] Pseudo-DC 4: Pseudo-DC refers to a controlled but unregulated voltage input / output, such as those found in the intermediate stages of power converters. A pseudo-DC port is intended to remain internal to the module. It serves as a connection node between the various components. For this type of port, the following functions are not required: hot-plug power connection, pre-charge system, overcurrent or overvoltage protection system, and direct current measurement, which represents potential cost savings.

[0049] System 10: this term will designate an assembly of modules whose characteristics are specific to managing energy for an on-site application according to its specific needs.

[0050] PUE (Power Usage Effectiveness): PUE is an indicator used to measure the energy efficiency of a data center. By extension, it can be applied to any system, for example, a microgrid. PUE evaluates efficiency by calculating the ratio of total energy used to the energy actually used by the application.

[0051] Examples of state-of-the-art converters include the bidirectional isolated converter via a high-frequency transformer (especially DC / DC), the bidirectional non-isolated DC / DC converter (optimal efficiency with buck converters), and the isolated converter. bidirectional DC / AC, the non-isolated bidirectional DC / AC converter (for battery, PV panel, turbine, etc.) and other non-isolated conversion elements.

[0052] The "module" topologies present in the prior art are for example the isolated rectifier (non-isolated AC / DC combined with an isolated DC / DC; 2 stages, 2 ports), a bidirectional DC / DC Buck / Boost topology (2 non-isolated DC / DCs; 2 stages, two ports, V_port1 > V_port2 and intermediate voltage > V_port1 and V_port2), a solar inverter (combination of one or more non-isolated DC / DCs combined with a single non-isolated DC / AC; 2 stages, 2 ports), a hybrid PV / battery solar inverter (combination of one or more non-isolated DC / DCs combined with a single non-isolated DC / AC (grid side) and a single bidirectional non-isolated DC / DC for battery connection; 2 stages, 3 ports). The structure and management of innovation

[0053] The object of the invention is to create an architecture based on conversion elements (see figure 4) which can be assembled at will, for example in a workshop, like Lego® bricks, to constitute modules which will be a marketable unit, these being themselves assembled into systems (see figures 6 and 7) used for energy management in order to optimize the PUE in micronetworks, data centers, etc.

[0054] In all existing modules on the market and in the state of the art, control is unique and globalized across all ports present (2 ports or 3 ports). This greatly facilitates the management of the zero-sum energy balance. The drawback is that each state-of-the-art module is fixed in its characteristics, limiting its use to a restricted range of equipment.

[0055] Thanks to the hierarchical structure proposed according to the invention, the microcontrollers 5 in the elements 2 are linked only to the controller module 6. They do not communicate directly with each other, although they operate in a perfectly coherent and coordinated manner. Furthermore, they concentrate a large number of calculations and tasks, thus relieving the controller module 6 of a significant workload. The situation is initially more complex but also more flexible. For example, according to the invention, creating a new module 6 with a new or any number of ports 3 will be simple and quick. The parallelization of modules 6 is Generally operational in their current state of the art as long as the electrical grid is present and on their AC port only. To our knowledge, there are no parallelizable and rack-mountable modules with more than 3 ports. Many hybrid UPSs are available as 3-port modules. Modular UPSs are 3-port modules. They are rack-mountable and can be parallelized, but very few are multidirectional.

[0056] In terms of power electronics, SiC MOSFETs and GaN will be used to increase the switching frequency (typically 140 kHz) and improve density and efficiency, while remaining economically viable. An intrinsic power balance will be targeted, preferably with a difference of less than 500 W, or <2.5%.

[0057] Advantageously, the AC / pseudo-DC brick will be designed to be compatible with various electrical configurations (three-phase, two-phase, single-phase), with the possibility of parallel connection (and in some cases series connection – isolated converters), with a wide input and output voltage range, minimum + / -30% of the nominal voltage (compliant with US and international standards), with or without a neutral connection. The voltage range can be wider but with a power derating. The components will ensure bidirectional energy flow. The components will be designed to achieve low electromagnetic emissions.

[0058] Even more advantageous, the focus will be on drastically reducing no-load or low-load losses (<0.1% of nominal power). In addition to optimizing energy flows, improving the power usage efficiency (PUE) involves deactivating equipment and modules during periods of low usage. Later, AI techniques will be incorporated to judiciously define when and how "sleep phases" are activated / deactivated. Practically speaking, the developments must include a low-power mode.

[0059] As is known from the state of the art in cooling, the cooling system for removing the heat produced by the components will be liquid or air-based, for example, forced air or preferably natural circulation, possibly using two-phase technology with recovery of waste heat for various applications such as electricity production or water heating.

[0060] The systems 10 derived from the platform created according to the invention incorporate all these characteristics and have no equivalent in the current state of the art.

[0061] The development stages of the invention are as follows: - to make the conversion element independent and autonomous: • integrate local control via PC equipped with DSP (Digital Signal Processing) functions operating at very high speed (e.g. 140KHz); • incorporate a local food supply; • build a part that is easily handled in the workshop and without risk of damage; • define interfaces (power and communication) robust enough to allow the creation of future conversion elements compatible and consistent with the operation of the module; • integrate EMC filters; • certify the conversion element as such to simplify the certification of modules and systems. - create a protective mechanical structure for the module that can be easily integrated into a cabinet (rackable); - Create the controller module (figure 7) which controls and synchronizes the PCs of the conversion elements: • continuously calculate the energy balance of inputs and outputs of the module to guarantee a zero sum even and despite load impacts (sudden transient variations); • receive and interpret instructions emanating from the system level; • synchronize the ports to meet the requirements of load sharing, fault tolerance, synchronization, phasing, etc.; • communicate at high speed (e.g. 10KHz) with the microcontrollers (pC) of the conversion elements; - design a universal test bench for the elements allowing for automatic programming and calibration.

[0062] Regarding the concept of modules easily integrated into a rack (rackable), preferably in vertical stacking in a standardized 19-inch bay, this is not self-evident and requires, according to the invention, the implementation of a series of technical means allowing easy and rapid integration: mechanical means for standardized fixing (known in themselves to the person skilled in the art), preferably means of quick fixing (wing nuts, clip fasteners, pop rivets, etc.), a position control of each module via a backplane card attached to the cabinet, cables and / or busbars to connect the elements, etc.

[0063] The principle of platform control is described below. (figure 7).

[0064] Each element, via a dedicated low-level controller (level 5), performs intelligent, high-speed PWM control (<0.5ms) autonomously, ignoring the control executed by other elements within the same module. This control is designed to ensure the combined operation of the elements, the flexibility and scalability of the platform, and their function in relation to the connected equipment. The only external data consists of instructions from the module's controller.

[0065] The controller for module 6 performs the following functions: • a balance of power between the different elements while ensuring the parallelization (or series connection) functions between modules, with a view to integrating the elements into a larger structure and respecting typical constraints such as "fail safe" redundancy, load impacts, etc.; • stabilization of the "pseudo DC" voltage common to all elements while respecting constraints with their respective priorities; and in particular: • Redundant communication between modules via a bus with integrated synchronization (e.g. via RS-485, 2 Mb / s): this function ensures reliable communication between modules, even in the event of failure, thanks to a synchronized redundant bus; • a master communication with the element controllers (e.g. via RS-422, 6x 6 Mb / s): management of the main communication with the controllers of the different elements via several high-speed communication lines; • a power flow control to manage a "pseudo-DC" + / - 465Vdc bus ("Vtank"): allows control and regulation of the power flow on the power bus to ensure stable operation; • management of the module's state machine ("behavior") and alarms: ensures the management of the module's operational state and supervises the generation and processing of alarms; • a power / current limitation (user, thermal derating, interaction with the network): imposes limits on power and current based on user needs, thermal constraints and interactions with the electrical network; • an Ethernet connection: enables communication via Ethernet, particularly for remote monitoring and control applications via energy management protocols such as MQTT; • Auxiliary functions (EEPROM, file system, diagnostics, software update, etc.): includes various secondary functions such as data storage in the EEPROM, diagnostic management and software update.

[0066] However, until now, the module's controller operated in a conventional manner, simultaneously driving all conversion stages. The new challenges are as follows: • a decentralization of tasks to the microcontrollers of the elements; • high execution and transmission speed to cope with transients, especially in a multiport context and with considerable power concentration; • the definition of a sufficiently robust operating procedure to support the introduction of new elements without adjustments, and thus preserve backward compatibility; • freeze the firmware as early as possible to meet the requirements of certification bodies which integrate the code into the certification protocol and impose re-certification after any change.

[0067] The internal energy storage located at the interface between stages (in this case, between the elements) is essential to ensure a proper response to transients (load impacts, grid or source disturbances, etc.). However, this storage also represents a cost and a source of losses. Its size will be reduced as the power flow control speed within the module improves, although there is no mathematical formula to determine the optimal size of this storage. Furthermore, the size of this storage must be such that it maintains the interoperability of the elements.

[0068] Intrinsic system control for operational consistency is ensured between the different levels (not shown). Since the control of a system composed of converters and their environment is organized in nested layers, the flexibility in converter configuration introduces combinatorial complexity. It will therefore be necessary to ensure that the control algorithms at all levels are interoperable or, at the very least, capable of detecting when the system is unable to function. system in a given configuration (for example, if no converter is configured in power balance, it is not possible to operate the system).

[0069] Creating a new conversion brick 2 (for example to control a wind turbine or a micro-turbine) is simple and quick and will allow the creation of new compatible systems without calling into question the other components of the set.

[0070] Note that the targeted structure is independent of the electrical network and manages flows internally through "pseudo-DC" connections 4 between the elements, a considerable advantage that should delight electrical network managers dissatisfied with the numerous nuisances generated by decentralized equipment. Module integration into the cabinet

[0071] According to one form of execution, a backplane card The backplane is supplied as a small interconnection card placed at each cradle that receives a module in the power conversion cabinet. There are therefore as many backplanes as there are modules that can be inserted into a single cabinet. These backplane cards are fixed within the system and are interconnected via a 16-wire flat cable, enabling digital communication between the modules. When a module is inserted into a cabinet, the module control card interconnects with the backplane card, and communication between modules is then possible via the isolated RS485 communication buses A and B, the Applicant's proprietary communication protocol.

[0072] This card enables other functionalities and acts as a link to the outside world: - Ethernet port: ideal for interfacing external monitoring and control; communication can be done with each module or with a master module (an interface card is present in each module); - digital inputs / outputs: allows connection to an emergency stop button, alarms or various controls of isolated contacts; - Detection of the module's hardware position within the cabinet and the system. This feature is new to the systems offered by the Applicant and will allow the module to automatically recognize its function within the system by recognizing its position. This will facilitate commissioning and replacement of defective modules by the technician and thus prevent any configuration errors related to the module's position; - Instant detection of module disconnection or poor connection within the system. This helps to stop power transfer if the connection is not perfect. Ultimately, this leads to a significant reduction in the potential formation of electrical arcs when removing the module from the system. This very useful feature ensures safe "hotplugging" of the modules.

[0073] To achieve this, a small, low-cost processor has been integrated, which includes internal memory, various digital I / Os, and a communication port. This microprocessor is only powered when the module is inserted. At that point, the module controller board supplies it with power via a +3.3V supply.

[0074] EXAMPLE An example of an application of the present invention is a medium-power energy system, typically 5-200 kW, but also capable of being competitive up to 20 MW by paralleling around one hundred modules, each module being able to reach up to 60 kW, or even 120 kW or 200 kW max, consisting of: - modular electronic power converters (~20 kW / element) multiport, rackable, parallelizable, with optimized density and efficiency, and highly configurable (adaptation to different assets with their own technical characteristics); - an industrial controller capable of digital communication with at least one module (which acts as a conduit for the complete system), the others local equipment (batteries, measuring devices, etc.), connected to the Internet network (IoT, Building Management System, remote Energy Management System, network managers, etc.) and highly configurable (control library, programming interface, etc.); - a cooling system, with the variant of cooling with heat recovery, allowing the heat produced by the converter elements to be evacuated or utilized. Reference symbols module 1, 1A, 1B, 1C 2 sub-modules or conversion elements 3 ports 4 pseudo-DC (voltage) 5 element controller 6 module controller 7 converter 8 DC or pseudo-DC network 9 Controller module-element link / interface 10 system 11 general network 12 control link between modules 13 AC load (house) 14 DC charging ports (electric vehicle, mobile phone) 15 renewable energy resources (wind, solar, biomass) 16 energy storage systems (battery, turbine, thermal) 17 converter 18 step-down transformer

Claims

DEMANDS 1. A power electronics power conversion system (10), suitable for use in a power station, comprising at least two multiport conversion modules, a first conversion module (1A) and a second conversion module (1B), each conversion module (1A, 1B, ...) comprising: - a plurality of removable sub-modules or elements (2), each sub-module or element (2) comprising a local or conversion controller (5), called the first-level controller; - a protective structure in the form of a chassis in which the sub-modules (2) are arranged; each conversion module (1A, 1B, ...) comprising a central or module controller (6), called the second-level controller, configured to exchange control data with the corresponding local controllers (5), said central controller (6) also being arranged in the protective structure; each sub-module (2) comprising a converter (7), at least one external AC or DC port (3) and one internal DC connector, said external port (3) and said internal DC connector being connected to the converter (7); each conversion module (1A, 1B, ...) comprising a common DC or pseudo-DC network or bus (4, 8) to which at least two of, preferably all, the sub-modules (2) are connected via their internal DC connector; characterized in that, in the power conversion system (10), each conversion module (1A, 1B, ...) is connected in series and / or parallel with one or more other conversion modules (1A, 1B, ... ), the module controllers (6) of the conversion modules (1A, 1B, ... ) communicating with each other via a link (12) to exchange system management data.

2. The energy conversion system (10) according to claim 1, characterized in that it comprises a system controller, called a third-level controller, for the overall control of an energy station comprising said system.

3. The energy conversion system (10) according to claim 1, characterized in that, in each conversion module (1, 1A, 1B, 1C, ...), at least two sub-modules (2) are configured so as not to exchange control data via their respective local controllers (5), control being then centralized via the central controller (6).

4. The energy conversion system (10) according to claim 1, characterized in that, in each conversion module (1, 1A, 1B, 1C, ...), at least two sub-modules (2) are configured so as to be connected to each other by mechanical fixings and electrical connections, the mechanical fixings being of the quick type and the electrical connections being cables or busbars.

5. The energy conversion system (10) according to claim 1, characterized in that, in each conversion module (1, 1A, 1B, 1C, ...), each sub-module (2) comprises an interface (9) including terminals ensuring the transfer of control data between the corresponding local controller (5) and the central controller (6) of the module (1, 1A, 1B, 1C, ...) when said sub-module (2) is arranged in the module (1, 1A, 1B, 1C, ...), the respective interfaces (9) being independent of each other.

6. The energy conversion system (10) according to claim 1, characterized in that it comprises at least one standardized cabinet or bay configured to accommodate one or more rackable conversion modules (1, 1A, 1B, 1C, ...).

7. The energy conversion system (10) according to claim 6, characterized in that it comprises for each module a backplane card attached to the cabinet for position control of each module and instantaneous detection of a disconnection or bad connection of a module, the controller of said module interconnecting with the backplane card for digital communication between the modules.

8. The energy conversion system (10) according to claim 1, characterized in that each conversion module (1, 1A, 1B, 1C, ...) comprises at least two ports, external and internal, and preferably 3 or more ports.

9. The energy conversion system (10) according to claim 8, characterized in that the conversion modules (1, 1A, 1B, 1C, ...) are connected in series or parallel via their respective external ports, the DC or pseudo-DC buses (4, 8) of the different conversion modules (1, 1A, 1B, 1C, ...) being independent of each other.

10. The energy conversion system (10) according to claim 8, characterized in that the conversion modules (1, 1A, 1B, 1C, ...) are of heterogeneous composition, namely that they differ in the number and nature of removable sub-modules or elements (2).

11. The energy conversion system (10) according to claim 1, characterized in that it is equipped with a water or air cooling system, forced or natural air, where appropriate of the two-phase type with heat recovery.

12. The energy conversion system (10) according to claim 1, characterized in that it covers a medium power range between 5kW and 20MW and preferably between 20kW and 200kW.

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