Full-Bridge Module Topology for Compact DC Circuit Breakers
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Solution Overview
Problem
Existing full-bridge-based hybrid direct current circuit breakers have a complex structure, require a large number of capacitors and IGBT devices, leading to increased volume, cost, and complicated control wiring, which affects reliability and compact design.
Innovation Solution
A full-bridge module with simplified topology, reduced passive elements, and unified fully-controlled power electronic devices, reducing the number of high-potential control units and simplifying electrical wiring, while achieving a compact and reliable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full-bridge-based hybrid direct current circuit breaker topology is used, then the circuit breaker can cut off fault current effectively, but it requires a large number of capacitors and IGBT devices, increasing the overall volume and device complexity
Solution Approach 1:
The patent combines multiple IGBT devices into a single integrated IGBT module, merging their functions into one unified component. This reduces the total number of discrete IGBT devices and capacitors needed in the circuit breaker topology, thereby decreasing device complexity and overall volume while maintaining the full-bridge structure's fault current breaking capability
Solution Approach 2:
The integrated IGBT module is designed to perform multiple functions simultaneously, serving as both the power switching element and the control element for multiple bridge legs. This multi-functional design reduces the number of separate components required, addressing the contradiction between reliability and device complexity
2Ease of operation
If each IGBT is driven separately with individual control units, then the circuit breaker can be controlled precisely, but the secondary wiring becomes complicated and driving power requirements increase
Solution Approach 1:
The patent merges multiple separate control units into a single integrated control unit that can drive the IGBT module. This consolidation reduces the complexity of secondary wiring by eliminating multiple separate control connections while maintaining precise control capability through integrated control logic and signal distribution within the module
Solution Approach 2:
The integrated control unit is designed with multi-functional capabilities to control multiple IGBT switches within the module simultaneously. This universal control approach reduces wiring complexity while preserving precise control over all switching operations through a single coordinated control system
3Reliability
If a large number of capacitors are used in parallel with each device, then the circuit breaker achieves good technical performance, but the overall volume increases and compact design becomes difficult
Solution Approach 1:
The patent merges multiple separate capacitor components into a shared capacitor structure that serves multiple devices simultaneously. This consolidation reduces the total volume of capacitors required while maintaining the necessary energy storage and voltage stabilization functions for reliable operation of the full-bridge circuit breaker
Solution Approach 2:
The patent employs a nested arrangement where capacitors are integrated within or alongside the IGBT module structure, nesting the capacitor components within the existing device footprint. This nesting approach reduces overall volume by eliminating separate capacitor mounting spaces while preserving the technical performance required for reliable fault current breaking
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
A full-bridge module, a hybrid direct current circuit breaker of a full-bridge module and an application method, the full-bridge module comprising: two power electronic units (1, 2, 3, 4), two diodes (5, 6), a resistor (R1) and a capacitor (C); the two power electronic units (1, 2, 3, 4) are in reverse series connection to form an upper bridge arm; the two diodes (5, 6) are in common anode series connection or common cathode series connection to form a lower bridge arm; and once the resistor (R1) and the capacitor (C) are in parallel connection, same are connected between the upper bridge arm and the lower bridge arm.