Hybrid Power Conversion System with Add-On Module
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Solution Overview
Problem
Existing power conversion systems struggle to integrate advanced battery technologies with legacy systems, leading to premature replacement of batteries and inefficiencies in power transfer between DC voltage sources.
Innovation Solution
A hybrid power conversion system that combines Toshiba's Super Charged Ion Battery (SCIB) with other DC power supplies, utilizing a modularized step-up topology and bidirectional isolated DC/DC converters to selectively connect and disconnect battery strings, enabling efficient power transfer and charging, and managing power flow through a system level controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If advanced battery technologies are integrated with legacy battery systems, then power transfer efficiency and system performance are improved, but device complexity increases due to the need for modularized topologies and bidirectional DC/DC converters
Solution Approach 1:
The system divides the power conversion function into separate bidirectional DC/DC converter modules, each handling specific battery strings. This segmentation allows independent optimization of each module while maintaining overall system efficiency, resolving the contradiction between improved power transfer and increased complexity by making the complexity modular and manageable.
Solution Approach 2:
The bidirectional DC/DC converters are designed to perform multiple functions: power transfer between different voltage sources, battery charging, and seamless integration of legacy and advanced battery technologies. This multi-functionality reduces the need for separate dedicated components, thereby improving power transfer efficiency without proportionally increasing system complexity.
2Adaptability or versatility
If modularized step-up topology with bidirectional DC/DC converters is used, then adaptability to different battery technologies is improved, but device complexity increases due to additional switching configurations and control requirements
Solution Approach 1:
The system employs dynamic switching configurations that can be adjusted in real-time based on the specific battery technology being integrated and the operational requirements. This dynamic adaptability allows the same modular topology to work with different battery types (lead-acid, SCiB, lithium-ion) without requiring separate dedicated circuits, thereby improving versatility while keeping the switching complexity manageable through software control.
Solution Approach 2:
The bidirectional DC/DC converters act as intermediary devices between different battery technologies and the DC grid/load. These intermediaries provide voltage matching, isolation, and controlled power transfer, enabling seamless integration of diverse battery types without directly connecting them to each other, thus reducing the overall system complexity while maintaining high adaptability.
3Loss of energy
If selective and independent connection of battery strings is implemented, then power transfer efficiency is maximized, but ease of operation decreases due to complex controller management requirements
Solution Approach 1:
The system incorporates feedback mechanisms where the controller continuously monitors the state of each battery string, load requirements, and power transfer efficiency. Based on this feedback, the controller automatically adjusts the switching configurations to optimize power transfer while maintaining simple operation. This closed-loop control resolves the contradiction by handling the complexity of selective connection automatically, allowing users to operate the system simply while achieving maximum efficiency.
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 maximizes power transfer efficiency between power sources, extends the life of legacy batteries, and allows for seamless integration of new battery technologies, reducing the need for frequent replacements and improving overall system performance.
Implementation Method 1
Power converters use high-powered DC/DC converters to transfer power between two DC voltage sources
Implementation Method 2
Batteries are a standard power source in power conversion systems
Data Source
AI summary
In accordance with disclosed embodiments, a power conversion system and method are provided. The power conversion system comprises a main power source configured to deliver drive power to a load and an add-on power module. The add-on power module comprises an isolated DC/DC converter and a low voltage source coupled in series with a high voltage source. The add-on power module is coupled to the main power source and the load and configured to output boost power to the load. The power conversion system further comprises a controller coupled to the main power source and the add-on power module, wherein the controller is configured to: determine that the load requires power from the main power source, and if so, direct boost power from the add-on power module to the load; and direct drive power from the main power source to the load when boost power falls below a predetermined threshold.