DC-DC Converter Bus Balancer for Split Voltage Control
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Solution Overview
Problem
Conventional DC-DC power converters in UPS systems have a high component count, cost, and size, and lack the ability to independently control split DC bus voltage levels, leading to potential imbalances during unique load conditions.
Innovation Solution
A DC-DC power converter system with a positive and negative bus interface, a transformer, and a bus balancer circuit, controlled by a controller to identify voltage imbalances and convert the system into an inverted buck-boost converter for energy transfer between the buses, using components like half-bridge, push-pull, or full-bridge converters and resonant inductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional DC-DC power converters are used in UPS systems, then power conversion is provided, but component count, cost, and size are high
Solution Approach 1:
The patent applies multi-functionality by enabling the DC-DC power converter to operate in multiple modes: normal power conversion mode and bus balancing mode. The same converter circuitry is used for both primary power conversion and secondary bus voltage balancing functions, eliminating the need for separate balancing components and reducing overall system complexity while maintaining voltage balance control capability
2Ease of operation
If conventional DC-DC power converters are used, then power conversion is provided, but the ability to independently control split DC bus voltage levels is lacking
Solution Approach 1:
The patent implements dynamic control by enabling the DC-DC converter to adaptively switch between normal operation and bus balancing operation based on real-time bus voltage conditions. The controller dynamically adjusts the converter's function to provide independent voltage control when imbalances are detected, while returning to standard power conversion when balanced, thus providing voltage control capability without permanent complexity
3Reliability
If bus imbalance correction is not implemented, then system simplicity is maintained, but reliability during unbalanced loads or fault conditions deteriorates
Solution Approach 1:
The patent applies self-service by enabling the DC-DC power converter to automatically detect bus voltage imbalances and perform self-correction through bus balancing operation. The system monitors its own operating conditions and autonomously switches to correction mode when needed, then returns to normal operation when balanced, providing enhanced reliability through self-regulation without adding external control complexity
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 actively corrects bus imbalances by enabling bidirectional power conversion, reducing component size and cost, and allowing independent control of DC bus voltage levels, enhancing reliability during unbalanced loads or fault conditions.
Implementation Method 1
a transformer coupled to the first converter segment, a second converter segment coupled to the transformer
Implementation Method 2
a resonant inductor coupled between the plurality of switches and the transformer
Data Source
AI summary
According to one aspect, embodiments of the invention provide a DC-DC power converter system comprising a positive bus interface, a negative bus interface, a positive battery interface, a negative battery interface, a first converter segment coupled to the positive bus interface and the negative bus interface, a transformer coupled to the first converter segment, a second converter segment coupled to the transformer, the positive battery interface, and the negative battery interface, a bus balancer circuit coupled to the transformer, and a controller configured to identify an imbalance between a positive voltage level on a positive DC bus and a negative voltage level on a negative DC bus, and in response to identifying the imbalance, operating the bus balancer circuit to convert the first converter segment, the transformer, and the second converter segment into an inverted buck-boost converter configured to transfer energy between the positive bus interface and the negative bus interface.