Intermediate Circuit Converter Coupling via Inductive Switching
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Solution Overview
Problem
Existing intermediate circuit converters face challenges in ensuring independent operation and load compensation between parallel circuits, leading to potential overloading and damage due to uneven energy distribution and dynamic imbalances.
Innovation Solution
The implementation of a control system with switching elements and diodes in the intermediate circuit converter allows for independent operation and dynamic linking/unlinking of intermediate circuits, enabling controlled energy flow and compensation between circuits, using a tax device to manage switching elements based on voltage and current conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If direct connection between intermediate circuits is implemented, then high dynamic operation is achieved, but rectifier overload and component damage can occur due to uneven energy distribution
Solution Approach 1:
The patent introduces coupling inductors as intermediary elements between parallel intermediate circuits. These inductors mediate the energy transfer between circuits, preventing direct short-circuit connections while enabling controlled energy flow. The inductors limit current surges and prevent rectifier overload by acting as current-limiting elements that maintain system dynamics without causing component damage.
Solution Approach 2:
The patent changes the connection parameters by introducing inductive coupling instead of direct resistive connection. This parameter change transforms the energy transfer mechanism from a high-current direct connection to a controlled inductive coupling, maintaining dynamic operation while preventing rectifier overload through the inductive impedance that limits current flow.
2Reliability
If brake resistors are switched on to dissipate energy, then rectifier overload is prevented, but energy is lost as heat and dynamic performance decreases
Solution Approach 1:
The patent converts the harmful effect of excess energy that would otherwise be dissipated as heat in brake resistors into a beneficial resource by enabling energy transfer to other intermediate circuits that may need additional energy. The coupling inductors facilitate this energy redirection, transforming waste energy into useful energy for other drives, thereby reducing overall energy loss while maintaining rectifier protection.
Solution Approach 2:
Instead of discarding excess energy through heat dissipation in brake resistors, the patent recovers this energy by transferring it through coupling inductors to other intermediate circuits that may require additional power. This energy recovery mechanism reduces total energy consumption while maintaining system reliability.
3Reliability
If components are oversized to ensure safe operation, then reliability is improved, but costs increase and dynamic performance decreases
Solution Approach 1:
The patent segments the energy management function by introducing separate coupling inductors for each intermediate circuit connection. This segmentation allows each rectifier to operate within its rated capacity while the inductors handle the energy balancing between circuits. As a result, standard-sized components can be used without oversizing, maintaining both reliability and dynamic performance.
4Adaptability or versatility
If parallel intermediate circuits are connected directly, then energy compensation between circuits is enabled, but high compensation currents can cause fires and destroy devices
Solution Approach 1:
The coupling inductors serve as protective intermediaries between parallel intermediate circuits. They enable energy compensation functionality while simultaneously limiting compensation currents to safe levels. The inductive impedance prevents dangerous current surges that would otherwise occur in direct connections, thereby eliminating fire hazards and device destruction risks while preserving energy compensation capability.
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 solution ensures safe and efficient operation by preventing overloading, allowing for flexible circuit operation, reducing thermal loads, and enabling energy reuse without the need for oversized components or high-loss resistors, thus extending component lifespan and reducing operational costs.
Implementation Method 1
The intermediate circuit converter 26, 27, 28 each has an intermediate circuit 3 with an intermediate circuit capacitor 4
Implementation Method 2
A first switching element 11 is arranged in the first line 9, to which a first diode 12 is switched in parallel
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to DC link converters comprising DC links (3) having DC link capacitors (4), which are connected to an energy supply (2) via rectifiers (1) and to loads (6) via inverters (5). The DC link converters have two terminals (7, 8), which are connected to the potentials (Q1, Q2) of the DC links (3) via lines (9, 10). In one of the lines (9) in each case, a switching element (11) is arranged, a diode (12) being connected in parallel with said switching element. Thus, when the switching elements (11) are open, the DC link capacitors (4) can be charged via the diodes (12) but cannot discharge. When the switching elements (11) are closed, the DC link capacitors (4) can at least discharge via the switching elements (11). The DC link converters have control devices (13), which control the switching elements (11) in dependence on the DC link voltages (U). In the lines (9), inductors (15) are arranged between the switching elements (11) and the terminals (7). The DC link converters have flyback diodes (16), which connect the lines (9, 10) to each other. Diode junction points (20), at which the flyback diodes (16) are connected to the one line (10), are arranged between the switching elements (11) and the inductors (15). Terminals of the DC link converters that are of the same type are connected to each other.