Three-Phase AC-DC Converter Control for Low Circulatory Current

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Solution Overview

Problem

Existing power supply equipment experiences inefficiencies during conversion of electrical power from alternating current (AC) to direct current (DC), particularly due to reactive power issues and circulatory currents when operating at non-unity gain, leading to reduced efficiency and conduction losses.

Innovation Solution

Implementing a control strategy for power supply equipment that includes controlling a secondary group of switches using four modes: high power buck, low power buck, high power boost, and low power boost, based on the ratio of input voltage to output voltage and gain, to minimize circulatory currents and optimize conversion efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional power supply equipment operates at non-unity gain, then voltage conversion is achieved, but circulatory currents increase causing conduction losses and reduced efficiency

Engineering Contradiction:
Improvevoltage conversion capabilityVSAvoidconduction losses
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The patent applies dynamics by making the switching control adaptive and variable based on operating conditions. The control system dynamically adjusts the switching patterns of power electronic devices according to the specific operating point (gain value), transforming a static conversion process into a dynamic one that optimizes efficiency across different operating conditions rather than being fixed at unity gain only.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the control parameters of the power supply equipment by introducing gain value-based control strategies. By monitoring and responding to changes in the gain parameter, the system adjusts its operation to minimize circulatory currents and conduction losses at each operating point, effectively using parameter change detection and response to resolve the efficiency problem.

Inventive Principle:
Principle #35Parameter changes

2Device complexity

If reactive power is not minimized, then power conversion simplicity is maintained, but efficiency is reduced due to circulatory currents

Engineering Contradiction:
Improvecontrol strategy complexityVSAvoidreactive power losses
Core Design Contradiction:
Device complexityVSLoss of energy

Solution Approach 1:

The patent implements feedback control by continuously monitoring the operating point and gain value, then using this information to adjust the switching control of power electronic devices. This closed-loop feedback mechanism enables the system to automatically minimize reactive power and circulatory currents based on real-time conditions, improving efficiency without requiring overly complex open-loop control strategies.

Inventive Principle:
Principle #23Feedback

3Loss of energy

If conversion efficiency is optimized, then energy loss is reduced, but conversion inefficiencies still exist in conventional equipment

Engineering Contradiction:
Improveconversion inefficiencyVSAvoidpower conversion effectiveness
Core Design Contradiction:
Loss of energyVSProductivity

Solution Approach 1:

The patent segments the power conversion process into distinct operating regions based on gain values, applying optimized control strategies for each segment. By dividing the conversion process into manageable segments with tailored control approaches, the system achieves higher overall efficiency while maintaining effective power conversion across the full operating range.

Inventive Principle:
Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The control strategy reduces circulatory currents and enhances the efficiency of power supply equipment by minimizing reactive power, thereby improving the conversion of AC to DC electrical power.

Implementation Method 1

a primary circuit that is electrically coupled to a primary wire of a transformer

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250392232A1Three phase to single phase power supply equipment
Publication Date: 2025.12.25 BORGWARNER INC
  • US20250392232A1 patent drawing
  • US20250392232A1 patent drawing
  • US20250392232A1 patent drawing

AI summary

A method of controlling power supply equipment that includes receiving alternating current (AC) electrical power at the power supply equipment; selecting a mode from the following possible modes: high power buck, high power boost, low power buck, or low power boost; generating gate signals based on the selected mode; and providing the generated gate signals to switches included in the power supply equipment that rectify alternating current (AC) into direct current (DC).