Bidirectional Power Converter Load Testing Without External Loads
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Solution Overview
Problem
Conventional power converter load testing methods require external loads, leading to significant power consumption, high costs, and limited throughput due to the need for separate testing equipment and space, while also being inefficient in energy usage and not suitable for simultaneous testing of multiple converters.
Innovation Solution
A test system that uses two identical bidirectional power converters to perform load testing without external loads, where energy is fed back between the converters, minimizing power loss and allowing for simultaneous testing without reconfiguration, using a data collection system to analyze test data and determine if the converters meet acceptable performance criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external loads are used for load testing power converters, then the power converters can be tested for defects, but significant power consumption occurs and costly dedicated test equipment is required
Solution Approach 1:
The power converter under test serves its own testing needs by using its identical counterpart as a bidirectional load. The tested converter operates in reverse mode to absorb and dissipate energy that would otherwise be lost, eliminating the need for external resistive loads and reducing power consumption significantly.
Solution Approach 2:
Instead of discarding energy through external resistive loads, the system recovers energy by feeding it back to the power converter under test in reverse mode. This energy recovery mechanism reduces overall power consumption and eliminates the need for costly external load equipment.
2Reliability
If external loads are used for load testing power converters, then the power converters can be tested, but costly and space-consuming dedicated test equipment is required
Solution Approach 1:
The power converter under test serves its own testing needs by using its identical counterpart as a bidirectional load. The tested converter operates in reverse mode to absorb and dissipate energy that would otherwise be lost, eliminating the need for external resistive loads and reducing power consumption significantly.
Solution Approach 2:
The identical power converter serves multiple functions: it acts as both a test subject and a test equipment (load). This multi-functionality eliminates the need for separate external load equipment, reducing both cost and space requirements while maintaining testing capability.
3Reliability
If separate external loads are used for each power converter, then each converter can be tested individually, but testing throughput is limited
Solution Approach 1:
The testing system merges two identical power converters into a single integrated test setup where both units can be tested simultaneously. By connecting them bidirectionally, the system allows parallel testing without requiring separate external loads for each converter, thereby doubling the testing throughput.
Solution Approach 2:
The identical power converter serves multiple functions: it acts as both a test subject and a test equipment (load). This multi-functionality eliminates the need for separate external load equipment, reducing both cost and space requirements while maintaining testing capability.
4Loss of energy
If regenerative load is used to reduce power consumption, then power loss is reduced, but the system is expensive and only tests a single power converter at a time
Solution Approach 1:
The power converter under test serves its own testing needs by using its identical counterpart as a bidirectional load. The tested converter operates in reverse mode to absorb and dissipate energy that would otherwise be lost, eliminating the need for external resistive loads and reducing power consumption significantly.
Solution Approach 2:
The testing system merges two identical power converters into a single integrated test setup where both units can be tested simultaneously. By connecting them bidirectionally, the system allows parallel testing without requiring separate external loads for each converter, thereby doubling the testing throughput.
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 approach reduces power loss to only that inherent in the converters, minimizes costs and space requirements, and increases testing throughput by eliminating the need for external loads and dedicated testing equipment, enabling efficient and effective evaluation of power converters.
Implementation Method 1
During the load testing, energy that is transferred from the second power converter to the third power converter is fed back to the second power converter. Similarly, energy that is transferred from the third power converter to the second power converter during the load testing is fed back to the third power converter.
Data Source
AI summary
A test system includes a first, second, and third power converter and a data collection system. The test system performs load testing on the second and third power converters without requiring any external load. The first power converter is supplied by an Alternating Current (AC) source. During a test cycle, the first, second, and third power converters are controlled such that the second power converter is supplied by an output current of the first power converter and a feedback current output by the third power converter. The third power converter receives current output by the second power converter and outputs the feedback current onto the second power converter. The data collection system receives power converter test characteristics (voltage, current, and temperature information) during the test cycle without any power being dissipated by an external load. Test information is used to determine whether the second and third power converters are defective.