Power Converter Leg Activation for Lifespan and Ripple Control
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Solution Overview
Problem
Power converters experience degradation over time, leading to malfunction due to repeated use, which affects their performance and lifespan.
Innovation Solution
A system and method for selectively activating legs of power converters, utilizing a controller with processors and memory to identify operating conditions, determine the number of legs to use based on parameters like duty cycle and utilization metrics, and dynamically activate or deactivate legs to optimize power transfer and extend lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all legs of the power converter are continuously activated to maintain high power transfer capability, then the power transfer efficiency is improved, but the degradation of internal components accelerates leading to reduced lifespan
Solution Approach 1:
The system dynamically adjusts the number of active legs based on real-time monitoring of component degradation metrics and power transfer requirements. The controller continuously evaluates system state and reconfigures which legs are active, transitioning from a static all-legs-active configuration to a dynamic selective activation strategy that adapts to changing component conditions.
Solution Approach 2:
The system changes the operational parameters of the power converter by varying the number of active legs from the maximum configuration to a reduced configuration based on component health metrics. This parameter change allows the system to operate at different capacity levels, reducing stress on degraded components while maintaining adequate power transfer capability.
2Reliability
If the number of active legs is reduced to extend converter lifespan, then component degradation is slowed, but the power transfer capability and efficiency decrease
Solution Approach 1:
The system implements a feedback mechanism where the controller continuously monitors component utilization metrics, degradation indicators, and power transfer performance. Based on this feedback, the controller adjusts the number of active legs to optimize the balance between extending component lifespan and maintaining adequate power transfer capability, rather than using a fixed reduced configuration.
Solution Approach 2:
The system dynamically determines the optimal number of active legs based on real-time system conditions and component health status. Rather than permanently reducing the number of active legs, the system adapts the configuration dynamically, allowing full power transfer capability when components are healthy and reduced capability when degradation is detected, thus maintaining the best possible balance between lifespan extension and productivity.
3Productivity
If selective leg activation is implemented to optimize power transfer, then efficiency is improved, but the complexity of control increases
Solution Approach 1:
The control system divides the power converter into independent leg modules, each with its own activation state. This segmentation allows the controller to independently manage each leg's operation based on specific criteria, simplifying the control logic compared to managing all legs as a single unit. The controller evaluates each leg's contribution to power transfer and activates only those needed for the current power level.
Solution Approach 2:
The system employs utilization metrics that automatically track and report the usage and degradation state of each leg. This self-service capability reduces the complexity of control by providing the controller with ready-made information about component health and usage patterns, eliminating the need for complex monitoring and analysis algorithms while still enabling optimized selective activation.
Data Source
AI summary
Presented herein are systems and methods of selectively activating legs of converters. The system can include a power converter comprising a plurality of legs to convert electrical power conveyed between a source and a load. The system can include a controller structured to be coupled with the power converter. The controller can identify a parameter defining an operating condition of the power converter. The controller can determine a number of legs of the power converter to use based on the parameter. The controller can identify a metric indicating a utilization of each leg of the plurality of legs. The controller can cause activation of at least a subset of legs of the plurality of legs in accordance with the number of legs and the metric, to convey the electrical power between the source and the load.