Bi-directional AC/DC Converter for Reversible Solid Oxide Fuel Cell Systems

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Solution Overview

Problem

Current grid-tied power systems for reversible solid oxide fuel cells (RSOFCs) require separate AC/DC converters for each mode of operation, complicating controls and increasing electrical footprint and cost.

Innovation Solution

A fully integrated RSOFC system with a bi-directional AC/DC converter and a common bus that allows power to flow bi-directionally between the RSOFC unit and the grid, eliminating the need for multiple converters and simplifying power distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate AC/DC converters are used for each mode of operation (fuel cell and electrolysis), then the system can operate in both modes, but the device complexity and electrical footprint increase

Engineering Contradiction:
Improvebi-directional operation capabilityVSAvoidnumber of converters
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines separate AC/DC converters for fuel cell mode and electrolysis mode into a single bi-directional AC/DC converter. This converter can operate in forward mode to convert AC to DC for electrolysis, and in reverse mode to convert DC to AC for fuel cell power generation, thereby reducing the total number of converters while maintaining full bi-directional operational capability

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The bi-directional AC/DC converter is designed to perform multiple functions: it can convert AC to DC for electrolysis mode, convert DC to AC for fuel cell mode, and provide grid connection functionality. This multi-functional design eliminates the need for separate dedicated converters for each operational mode

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate AC/DC converters are used for each mode of operation, then mode-specific power conversion is achieved, but the system cost increases

Engineering Contradiction:
Improvemode-specific power conversionVSAvoidsystem cost
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple mode-specific converters into a single bi-directional converter unit, reducing the total component count, material requirements, and assembly complexity, thereby lowering the overall system manufacturing cost while preserving mode-specific power conversion capabilities

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The bi-directional converter is designed as a universal power conversion unit that can handle both electrolysis (AC to DC) and fuel cell generation (DC to AC) operations, eliminating the need for purchasing and installing separate dedicated converters for each mode, thus reducing system cost

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If separate AC/DC converters are used for each mode, then independent power control is achieved, but the control system complexity increases

Engineering Contradiction:
Improveindependent power controlVSAvoidcontrol system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the control functions of separate converters into a single control system for the bi-directional AC/DC converter. This unified controller manages both AC to DC conversion for electrolysis and DC to AC conversion for fuel cell mode, reducing control system complexity while maintaining independent power control capability for each operational mode

Inventive Principle:
Principle #5Merging (Combining)

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

This configuration reduces system complexity and cost while enabling efficient operation in both fuel cell and electrolysis modes, allowing for seamless power generation and storage, and grid stabilization.

Implementation Method 1

The bi-directional AC/DC converter is coupled to the RSOFC unit, and is configured to convert direct current (DC) electrical power produced by the RSOFC unit into outgoing alternating current (AC) power, and to convert incoming AC power into DC power for consumption by the RSOFC unit in electrolysis mode

Methodology Applied
Scientific EffectElectrical Energy Conversion:

Implementation Method 2

The RSOFC unit has a fuel cell mode, wherein the RSOFC unit produces electrical power from fuel, and an electrolysis mode, wherein the RSOFC unit consumes electrical power to produce the fuel

Methodology Applied
Scientific EffectElectrochemical Oxidation:

Implementation Method 3

an electrolysis mode, wherein the RSOFC unit consumes electrical power to produce the fuel

Methodology Applied
Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS10770742B2Electrical power distribution system and method for a grid-tied reversible solid oxide fuel cell system
Publication Date: 2020.09.08 THE BOEING CO
  • US10770742B2 patent drawing
  • US10770742B2 patent drawing
  • US10770742B2 patent drawing

AI summary

A Reversible Solid Oxide Fuel Cell (RSOFC) system includes a Reversible Solid Oxide Fuel Cell (RSOFC) unit, a bi-directional alternating current/direct current (AC/DC) converter, coupled to the RSOFC unit, a common bus, coupled to the bi-directional AC/DC converter and to a power grid, and a plurality of RSOFC subsystems, coupled to receive power only through the common bus. The RSOFC unit has a fuel cell mode, wherein the RSOFC unit produces electrical power from fuel, and an electrolysis mode, wherein the RSOFC unit consumes electrical power to produce the fuel. The bi-directional AC/DC converter is coupled to the RSOFC unit, and is configured to convert direct current (DC) electrical power produced by the RSOFC unit into outgoing alternating current (AC) power, and to convert incoming AC power into DC power for consumption by the RSOFC unit in electrolysis mode.