Hierarchical Control Network for Power Converter Reliability
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Solution Overview
Problem
Existing converter systems with controllable power semiconductor switches face challenges in flexibility and reliability due to the need for numerous fixed communication lines between a central control device and control modules, which increases complexity and error risk, and requires redundant lines to avoid failures, thereby increasing costs.
Innovation Solution
A hierarchical communication network with a tree structure is implemented, where control modules form connections with each other to create multiple paths, allowing data to be exchanged efficiently through a master node connected directly to the central control device, and control modules can forward and process data, reducing the number of communication lines and enhancing redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated communication lines are provided between the central control device and each control module, then reliable communication is achieved, but the number of communication lines increases significantly and flexibility is reduced
Solution Approach 1:
Multiple control modules are connected to a common communication bus, merging individual communication channels into a shared medium. This reduces the total number of communication lines from N dedicated lines to a shared bus structure, while maintaining communication reliability through protocol-based access control and error handling mechanisms.
Solution Approach 2:
The communication bus serves multiple functions: it carries control signals from the central control device to multiple control modules, enables data exchange between control modules, and provides a universal interface for various types of communication traffic. This multi-functional design eliminates the need for separate dedicated lines for each function.
2Manufacturing precision
If each communication line has a defined and fixed length, then signal integrity is maintained, but the flexibility of the system structure is reduced
Solution Approach 1:
The communication network topology is made dynamic and reconfigurable. Control modules can be added, removed, or repositioned along the communication bus without requiring fixed-length connections to the central control device. The system adapts to different configurations while maintaining signal integrity through impedance matching and protocol-based error correction.
Solution Approach 2:
Intermediate control modules act as mediators in the communication network. They can relay signals between the central control device and other control modules, enabling flexible system expansion without requiring direct fixed-length connections from every module to the central device. This intermediary structure maintains signal quality while providing topological flexibility.
3Reliability
If redundant communication lines are provided to avoid errors, then reliability is improved, but costs and effort increase
Solution Approach 1:
The communication protocol incorporates feedback mechanisms including error detection, error correction, and automatic retransmission. When communication errors occur, the receiving module requests retransmission, ensuring reliable data delivery without requiring physical redundant communication lines. This software-based redundancy is more cost-effective than duplicating physical infrastructure.
Solution Approach 2:
The system uses parameter-based error handling and adaptation. Communication parameters such as data rate, voltage levels, and timing can be adjusted dynamically to optimize reliability for different operating conditions. This parameter flexibility allows the system to achieve high reliability without increasing physical redundancy, by adapting to environmental conditions and error patterns.
Data Source
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AI summary
The invention relates to a control system (35, 40) for controlling a plurality of controllable units with a central control device (30) and a plurality of control modules (32-34, 41-56), each of which is assigned to one of the units to be controlled, wherein the central control device is equipped for exchanging digital data with each control module.The invention is characterized in that the control modules form a communication network, wherein each control module is connected to at least one other control module via a communication line, enabling data exchange between them, one of the control modules is directly connected to the central control unit as the master node (35, 46) of the communication network, and the control modules are configured to form a communication network within the communication network, so that data exchange between the central control unit and each control module can be carried out via an assigned communication path within the communication network. Furthermore, the invention relates to a converter arrangement (1) with a plurality of switching modules (26-28) with controllable power semiconductor switches, characterized by the control system according to the invention.Furthermore, the invention relates to a method for controlling controllable power semiconductor switches of the converter arrangement by means of the control system.