Battery-Backed Power Converter for Single-Phase to Three-Phase Supply

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing power distribution systems face challenges in efficiently powering industrial three-phase 400 VAC or 480 VAC equipment in locations with single-phase voltage inputs, requiring expensive and inconvenient solutions such as hiring electricians, renting generators, or upgrading infrastructure, and are limited by power source inconsistencies.

Innovation Solution

A power converter system that receives single-phase AC voltage inputs between 100 VAC and 240 VAC, using a battery charge controller and three-phase inverter to convert power, allowing for supplemental power from a battery to meet peak demands and act as an uninterruptable power supply, capable of operating independently of the primary power grid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a power transformer is used to produce three-phase 400 VAC or 480 VAC power output where power source may not be capable of providing such power, then the equipment can be powered in locations with single-phase voltage inputs, but the system is limited by power source inconsistencies and cannot meet peak power demands

Engineering Contradiction:

Improveability to power equipment in varied voltage environmentsVSAvoidsystem performance under power source inconsistencies

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The battery is charged in advance during periods when power input is available, storing energy beforehand to ensure reliable operation during peak demands or power inconsistencies. The battery charge controller proactively manages charging during normal operation to prepare for future power needs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically switches between power input and battery supplementation based on real-time power requirements. The battery charge controller continuously monitors and adjusts the power distribution, transitioning between charging mode and power supplementation mode as conditions change.

Inventive Principle:

Principle #15Dynamics

2Power

If an industrial three-phase generator is rented or bought to power equipment in locations with single-phase voltages, then sufficient power can be provided, but the generator is loud, large, and inconvenient to use

Engineering Contradiction:

Improvepower output capabilityVSAvoidconvenience of use

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The system merges the compact power converter with a battery storage unit, combining the functions of power conversion and energy storage in a single integrated device. This eliminates the need for separate large generators while maintaining sufficient power output capability through battery supplementation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical generator system with an electrical power conversion system using a three-phase inverter and battery. This substitution eliminates the mechanical components that produce noise and require physical space, resulting in a quieter, more compact solution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If a power transformer is used to convert single-phase voltage to three-phase voltage, then equipment can be powered in remote locations, but the system cannot operate independently when external power is unavailable

Engineering Contradiction:

Improveability to operate in remote locationsVSAvoidcontinuous operation capability

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The battery is charged in advance during periods when external power input is available, storing energy beforehand to enable independent operation. This preliminary charging action ensures the system can operate autonomously in remote locations without continuous external power supply.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The power converter system is designed with multi-functionality, serving both as a power conversion device when external power is available and as an independent power source when it is not. The battery charge controller and three-phase inverter work together to provide universal operation in both grid-connected and standalone modes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If expensive solutions such as hiring electricians or upgrading infrastructure are used to power industrial equipment, then reliable three-phase power can be provided, but the cost and time required are prohibitively high

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidinstallation cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system segments the power supply solution into a portable, self-contained unit that can be deployed without infrastructure changes. Instead of requiring expensive electrical installations, the power converter with battery is divided into modular components that can be easily transported and set up at any location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a cost-effective power conversion solution that eliminates the need for expensive permanent installations. The portable power converter with battery represents a temporary, relocatable alternative to permanent electrical infrastructure, reducing both initial installation costs and long-term expenses.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Enables convenient and efficient powering of industrial equipment in varied voltage and frequency environments, reducing the risk of equipment damage from power inconsistencies and extending operation without external power sources, through simultaneous charging and power drawing capabilities.

Implementation Method 1

receive a power input at a battery charge controller. The power input may be converted to a DC voltage

Methodology Applied

Scientific EffectAC to DC conversion:

Implementation Method 2

The DC voltage may be converted back to an AC voltage using a three-phase inverter

Methodology Applied

Scientific EffectDC to AC conversion:

Implementation Method 3

Methodology Applied

Scientific EffectElectrical energy storage: Battery (electricity)

Data Source

PatentUS20230420980A1Power converter systems

Publication Date: 2023.12.28 SISU DEVICES LLC

AI summary

This disclosure describes systems, methods, and devices for power distribution systems that are capable of receiving and converting a variety of input power options. The power converter system may convert an AC power input into DC power and supplying this to a battery within the system. The power converter system may determine a first power requirement for a load. The power converter system may establish whether the power input is less than the first power requirement for the load. The power converter system may power, responsive to the determination that the power input is less than the first power requirement for the load, the load using a combination of the power input and a supplemental power supply from the battery, wherein the DC power from the battery is converted back to AC power using a phase inverter in the power converter system.