Common Core Inductor for DC-AC Power Converter Cost Reduction

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Solution Overview

Problem

Existing power converter systems that convert direct current (DC) to alternating current (AC) for renewable energy sources incur increased costs due to the use of inductors for filtering voltage and current variations.

Innovation Solution

A power converter system with an inverter having three phases, each with a plurality of bridges and switches, coupled to separate inductors with multiple windings about a common core, providing high effective inductance for filtering while reducing inductor costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If inductors are used to filter voltage and current variations in DC to AC power converters, then the quality of AC power output is improved, but the cost of the power converter increases

Engineering Contradiction:

Improvequality of AC power outputVSAvoidcost of power converter

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple inductor windings around a common core structure, merging separate inductor functions into a single integrated component. This reduces the total number of discrete inductor components needed while maintaining the filtering quality, thereby reducing overall cost without sacrificing power output quality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common core inductor structure serves multiple functions simultaneously - it provides filtering for multiple phases of AC power conversion while maintaining compact size. This multi-functionality reduces the overall component count and system complexity, addressing the cost issue while preserving the necessary filtering quality

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system effectively filters power for an electrical distribution network, reducing costs by utilizing a common core and multiple winding structure in inductors, thereby enhancing efficiency and cost-effectiveness.

Implementation Method 1

each inductor includes a plurality of windings positioned about a common core. An output of each bridge is coupled to a separate winding of the inductor

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentEP2466735B1Power generation system, power converter system, and methods of converting power

Publication Date: 2022.01.26 GENERAL ELECTRIC CO

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AI summary

A power converter system includes an inverter (110) including a first bridge (210) and a second bridge (212), wherein each of the first bridge and the second bridge includes at least one switch (202). The power converter system also includes an inductor (226) including a first winding (228) coupled to an output of the first bridge and a second winding (230) coupled to an output of the second bridge.