Three-Phase AC-DC Converter Parallel Interleaving Control

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Solution Overview

Problem

Conventional three-phase power converters face challenges in reducing harmonic content in input current and managing heat dissipation in electrolytic capacitors, leading to increased volume and cost, and reduced power density.

Innovation Solution

A three-phase AC-DC converter circuit with multiple parallel-connected AC-DC conversion modules and a control system that sets a predetermined phase difference between driving control signals of AC-DC converters, operating in a parallel interleaving mode to reduce input current ripple and inductance, thereby alleviating heat dissipation issues and enhancing power density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If inductance is increased by increasing the inductor's volume in the PFC circuit or in the EMI filter, then the harmonic wave of the input current is reduced, but the volume of the power converter is increased

Engineering Contradiction:
Improveharmonic wave of input currentVSAvoidvolume of power converter
Core Design Contradiction:
Object-generated harmful factorsVSVolume of stationary object

Solution Approach 1:

The patent divides the single-phase PFC circuit into three separate single-phase PFC circuits, each handling one phase of the three-phase input. This segmentation allows each phase to independently process current ripple, reducing the total inductance required compared to a single-phase design handling the same total power. The segmented approach transforms the harmful current ripple into a manageable characteristic at the phase level rather than requiring large filtering inductors at the system level.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent changes the operating parameters by introducing phase shifts between the three single-phase PFC circuits. Each phase operates with a different switching phase angle, which transforms the current ripple characteristics. This parameter change allows the ripples from different phases to partially cancel each other out, reducing the overall harmonic content without requiring increased inductance.

Inventive Principle:
Principle #35Parameter changes

2Loss of energy

If the number or volume of the electrolytic capacitor is increased, then the equivalent series resistance is reduced and the loss is reduced, but the volume of the whole system is increased

Engineering Contradiction:
Improveequivalent series resistance lossVSAvoidvolume of power converter
Core Design Contradiction:
Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent segments the DC bus capacitor function across three separate single-phase PFC circuits, each with its own capacitor. This distribution of capacitance function reduces the stress on any single capacitor, allowing smaller capacitors to be used while maintaining the same overall energy buffering capability. The segmented capacitor arrangement reduces the total volume compared to a single large capacitor while achieving lower equivalent series resistance through parallel distribution.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent combines the capacitor functions of three separate single-phase PFC circuits to achieve the overall energy buffering function. By merging the capacitive energy storage across three phases with phase-shifted operation, the system achieves reduced RMS current through the capacitors, lowering equivalent series resistance losses without requiring a single large capacitor volume.

Inventive Principle:
Principle #5Merging (Combining)

3Temperature

If the heat dissipation capability of the electrolytic capacitor is improved by increasing the amount of wind passing through the system, then the temperature rise is reduced, but the system complexity is increased

Engineering Contradiction:
Improvetemperature rise of electrolytic capacitorVSAvoidheat dissipation system complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent segments the heat generation sources into three separate single-phase PFC circuits with distributed capacitors. This segmentation distributes the heat dissipation load across multiple smaller components rather than concentrating it in a single large capacitor. The phase-shifted operation further distributes thermal stress over time, reducing peak temperatures without requiring complex active cooling systems.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent enables self-service heat management through phase-shifted operation of three single-phase PFC circuits. The inherent phase differences cause the peak current and heat generation events to be distributed across different time intervals, allowing passive heat dissipation to be more effective. This self-service approach reduces temperature rise without adding complex active cooling mechanisms.

Inventive Principle:
Principle #25Self-service

4Reliability

If a large electrolytic capacitor is connected to the DC bus, then the difference between transient powers of pre-stage and post-stage circuits is balanced, but the power density is reduced

Engineering Contradiction:
Improvepower balance stabilityVSAvoidpower density
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent segments the power buffering function across three separate single-phase PFC circuits, each with its own capacitor. This segmentation allows the power balance function to be distributed rather than concentrated in a single large capacitor. The combined effect of three smaller capacitors with phase-shifted operation provides the necessary transient power balance while occupying less total volume, thus maintaining higher power density.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent changes the operational parameters by introducing phase shifts between the three single-phase PFC circuits. This parameter change transforms the power transfer characteristics, allowing the pre-stage and post-stage circuits to exchange power more efficiently. The phase-shifted operation reduces the peak current demands on the DC bus capacitor, enabling smaller capacitor volumes while maintaining power balance stability.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS9019733B2Three-phase AC-DC converter circuit and conversion method and control system thereof
Publication Date: 2015.04.28 DELTA ELECTRONICS (SHANGHAI) CO LTD
  • US9019733B2 patent drawing
  • US9019733B2 patent drawing
  • US9019733B2 patent drawing

AI summary

The embodiment of present invention provides a three-phase AC (Alternating Current)-DC (Direct Current) converter circuit, conversion method and the control system thereof. The converter circuit includes a three-phase AC power source having a first output terminal, a second output terminal and a third output terminal; a first AC-DC conversion module, a second AC-DC conversion module and a third AC-DC conversion module electrically connected to the first output terminal, the second output terminal and the third output terminal of the three-phase AC power respectively, and respectively have N1 pieces, N2 pieces and N3 pieces of AC-DC converters which are connected in parallel; and a DC side output terminal electrically connected to the parallel-connected output terminals of the first AC-DC conversion module, the second AC-DC conversion module and the third AC-DC conversion module, wherein at least one of N1, N2 and N3 is greater than or equal to 2.