Fuel Cell Charging Station Power Module Architecture
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Solution Overview
Problem
Existing electrical power systems face challenges in synchronizing alternative power sources, such as fuel cells, solar arrays, and wind turbines, which require multiple stages of power conversion, increasing costs and complexity, and complicating the operation of distributed generators and electric vehicle battery charging systems.
Innovation Solution
A system comprising a plurality of power modules, including fuel cell segments, and an uninterruptible power module (UPM) with an input/output module (IOM) that allows for direct power delivery to loads from either the grid or fuel cell segments, reducing the need for bidirectional inverters and enabling efficient parallel operation of power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple stages of power conversion are used to deliver DC power from alternative power sources to AC motors, then the motors can be controlled with variable frequency drives, but the system cost increases and efficiency decreases
Solution Approach 1:
The patent extracts the AC motor and variable frequency drive from the power conversion chain, replacing them with a DC motor controlled by a DC-DC converter. This eliminates the need for bidirectional inverters and multiple conversion stages, directly addressing the energy loss problem while maintaining motor control capability through the DC-DC converter.
Solution Approach 2:
The patent substitutes the mechanical/electrical AC motor system with a DC motor system that operates directly from the DC power source. This replacement eliminates the need for complex power conversion equipment (inverters, rectifiers, variable frequency drives) and reduces energy losses associated with multiple conversion stages.
2Loss of energy
If bidirectional inverters are used to deliver power from fuel cell segments to loads, then power can be delivered efficiently, but the device complexity increases
Solution Approach 1:
The patent removes the bidirectional inverter from the system by directly connecting the DC-DC converter to the DC power source from fuel cell segments. This extraction eliminates the complexity of inverter configuration while maintaining efficient power delivery through the simplified DC-DC conversion architecture.
Solution Approach 2:
The patent introduces a DC-DC converter as an intermediary device between the DC power source and the load, replacing the complex bidirectional inverter. This intermediary simplifies the power delivery path while maintaining efficiency through direct DC-to-DC conversion without requiring bidirectional AC/AC conversion.
3Reliability
If alternative power sources are synchronized with the electrical grid, then power can be delivered reliably, but the system complexity increases due to synchronization requirements
Solution Approach 1:
The patent replaces the grid-synchronized AC power system with a standalone DC power system from alternative sources. This substitution eliminates synchronization requirements entirely, as DC systems do not require frequency and phase alignment with the grid, thereby maintaining reliability while reducing system complexity.
Solution Approach 2:
The patent extracts the synchronization function from the power delivery system by using direct DC coupling between alternative power sources and loads. This removal of the synchronization requirement eliminates the need for complex control systems while maintaining reliable power delivery through the inherent stability of DC systems.
4Adaptability or versatility
If multiple power conversion stages are used in the system, then power can be delivered to different loads, but the system cost increases
Solution Approach 1:
The patent creates a universal DC power platform that can serve multiple load types through a single DC-DC converter architecture. This multi-functional approach allows the same basic converter design to accommodate different load requirements, reducing overall system cost compared to having separate conversion systems for each load type.
Solution Approach 2:
The patent uses modular DC-DC converter designs that can be replicated and scaled to meet different power delivery requirements. This copying approach allows standardization of the converter architecture, reducing development and manufacturing costs while maintaining adaptability to different loads through parameter adjustment rather than complete redesign.
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 configuration enhances the efficiency and reliability of power delivery to electric vehicle battery charging systems by minimizing power conversion stages, reducing costs, and improving the synchronization of alternative power sources, while allowing for flexible operation with or without a grid reference.
Implementation Method 1
A system comprising a plurality of power modules, including fuel cell segments
Data Source
AI summary
A battery charging station receives power from two or more sources and supplies power to charge batteries of electric vehicles and devices.