DC Micro-Grid Controller for Fuel Cell Power Conversion

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Solution Overview

Problem

Electrical power systems that combine alternative power sources, such as fuel cells, solar arrays, and wind turbines, face inefficiencies and increased complexity due to multiple stages of power conversion, particularly when DC power needs to be converted to AC for 3-phase AC motors, leading to higher costs and reduced efficiency.

Innovation Solution

A fuel cell system architecture that includes a uninterruptable power module (UPM), an input/output module (IOM), and power modules, which use DC/AC inverters to manage power distribution, allowing for direct AC power delivery to loads and synchronization with the grid, reducing the need for additional power conversion stages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple stages of power conversion are used to convert DC power to AC for 3-phase AC motors, then the system can operate alternative power sources with the electrical grid, but the system complexity and cost increase

Engineering Contradiction:

Improveability to combine alternative power sources with electrical gridVSAvoidnumber of power conversion stages

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates unnecessary intermediate power conversion stages from the system. By using DC/AC inverters that can directly convert DC power from alternative sources to AC power suitable for 3-phase motors and grid synchronization, the system removes redundant conversion components while maintaining the ability to operate alternative power sources with the electrical grid.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The DC/AC inverter is designed to perform multiple functions: converting DC to AC for motor operation, synchronizing with the electrical grid, and providing power management capabilities. This multi-functional approach reduces the need for separate dedicated components for each function, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If multiple stages of power conversion are used, then power can be delivered to AC motors, but system cost increases

Engineering Contradiction:

Improveability to deliver power to AC motorsVSAvoidsystem cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent removes redundant power conversion stages that increase system cost. By implementing a streamlined DC/AC conversion process using inverters that can directly output AC power suitable for 3-phase motors, the system eliminates unnecessary intermediate conversion equipment, thereby reducing manufacturing costs while maintaining full operational capability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Power

If multiple stages of power conversion are used, then power conversion can be performed, but system efficiency decreases

Engineering Contradiction:

Improvepower conversion capabilityVSAvoidsystem efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent extracts and eliminates intermediate power conversion stages that cause energy losses. By implementing direct DC/AC conversion using efficient inverters, the system minimizes the number of conversion steps, thereby reducing cumulative energy losses and improving overall system efficiency while maintaining full power conversion capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10873099B1Storage system controller

Publication Date: 2020.12.22 BLOOM ENERGY CORP

AI summary

Systems and methods are provided for creating and operating a Direct Current (DC) micro-grid. A DC micro-grid may include power generators, energy storage devices, and loads coupled to a common DC bus. Power electronics devices may couple the power generators, energy storage devices, and loads to the common DC bus and provide power transfer.