Adaptive PFC Converter Topology for Fault-Tolerant Reconfiguration
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Solution Overview
Problem
Existing power converter topologies fail to address fault management and system reliability issues, shutting down when a single component fails, even in multi-converter module configurations.
Innovation Solution
Adaptive power converter topologies with boost inductors, switches, and diodes, including Delta or Vienna converters, utilize additional switches for synchronous operation and reconfiguration to maintain functionality as full-bridge converters in case of faults, supported by digital control algorithms for fault tolerance and isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single power conversion pathway is used, then the converter structure is simple, but the system shuts down when a single component fails, reducing reliability
Solution Approach 1:
The power converter is divided into multiple independent converter modules (first converter module, second converter module, etc.), each with its own power conversion pathway. These modules operate in parallel to share the total power load, so that a failure in one module does not cause the entire system to shut down, thereby improving reliability while maintaining manageable complexity through modular design
Solution Approach 2:
The controller dynamically adjusts the operation of different converter modules based on detected faults. When a component failure is detected in one module, the controller automatically redistributes the power conversion tasks to remaining healthy modules, enabling the system to adapt its configuration in real-time to maintain operation and improve reliability
2Productivity
If multiple converter modules are used in parallel or interleaved, then converter efficiency and available power increase, but the system still shuts down when a single component fails in any module
Solution Approach 1:
The controller implements dynamic fault detection and adaptive reconfiguration across multiple converter modules. When a component failure is detected in any module, the controller automatically adjusts the operational status of other modules to compensate, redistributing power conversion tasks dynamically. This allows the system to maintain high availability and efficiency while achieving fault tolerance through real-time adaptation rather than static redundancy
Solution Approach 2:
The controller continuously monitors the operational status of components in all converter modules and uses this feedback to make real-time decisions about module operation. When a fault is detected, the feedback mechanism triggers automatic reconfiguration of the remaining healthy modules to maintain system operation, thereby achieving both high productivity and fault tolerance through closed-loop control
3Reliability
If additional switches are added for synchronous operation and reconfiguration capability, then fault tolerance and reliability improve, but device complexity increases
Solution Approach 1:
The additional switches are designed to serve multiple functions: during normal operation, they enable synchronous switching and improve power conversion efficiency; during fault conditions, they enable reconfiguration of the converter topology to bypass failed components. This multi-functionality allows the system to achieve fault tolerance without proportionally increasing complexity, as the same hardware components serve both efficiency improvement and reliability enhancement purposes
Data Source
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Figure 3A
AI summary
A method includes operating a power converter (100, 200, 300, 400) in a first mode of operation, where the power converter includes multiple first switches (106a-106f, 206a-206f, 306a-306r, 407b) and multiple boost diodes (108a-108f, 208a-208f, 308a-308l, 324a-324f, 411a, 424) coupled to multiple first rails (104a-104c, 204a-204c, 304a-304c, 404a-404c). Each first rail is also coupled to a different one of multiple boost inductors (102a-102c, 202a-202c, 302a-302c, 402a-402c), and the power converter is coupled to multiple second rails (112a-112b, 212a-212b, 312a-312b, 412a-412b). The power converter in the first mode converts electrical power transported between the first and second rails. The method also includes, during the first mode of operation, operating multiple second switches (116a-116f, 216a-216f, 316a-316l, 326a-326f, 411b, 426) coupled in parallel across the boost diodes as synchronous switches. Each second switch is coupled across a different one of the boost diodes. The method further includes switching the power converter to a second mode of operation in which the first switches are deactivated and the second switches and the boost diodes operate as a full-bridge power converter.