Integrated Power Converter Modules for AC-DC and DC-DC Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and cost inefficiency of electronic power converters in electromechanical power transmission chains, due to numerous converter stages and high numbers of power electronic components, complicate component arrangement and cabling, and increase implementation and costs.
Innovation Solution
Implementing an electronic power converter with integrated modules that combine multiple converter stages, such as a first module for a three-phase AC-to-DC converter stage and a second module for DC-to-DC converter stages, including overvoltage protection, to increase integration level and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate converter stages are used to achieve different power conversion functions (AC-to-DC, DC-to-DC), then the power conversion capabilities are comprehensive and effective, but the device complexity and number of components increase significantly
Solution Approach 1:
The patent combines multiple converter stages (AC-to-DC converter and DC-to-DC converter) into a single integrated power converter device. The switching circuit includes switching branches that can be configured to perform different conversion functions, reducing the number of separate devices needed while maintaining comprehensive power conversion capabilities.
Solution Approach 2:
The power converter is designed with switching branches that can operate in multiple modes: the first switching branch performs AC-to-DC conversion, while the second and third switching branches perform DC-to-DC conversion. This multi-functional design allows a single device to replace multiple specialized converter stages.
2Device complexity
If the integration level of the electronic power converter is increased by using modules, then the arrangement of components and cabling is simplified, but the challenge of implementing different converter stages (AC-to-DC and DC-to-DC) with integrated modules increases
Solution Approach 1:
The power converter is divided into modular switching branches, where each branch can be independently configured for specific conversion functions. The switching circuit comprises multiple switching branches that can be selectively activated, allowing flexible implementation of different converter stages while maintaining modular architecture for ease of assembly and manufacturing.
3Adaptability or versatility
If a high number of power electronic components are used to implement multiple converter stages, then the power conversion functions are comprehensive, but the cost and cabling complexity increase
Solution Approach 1:
The patent merges multiple converter functions into a single integrated circuit with shared components. The switching branches share common electrical nodes and can be controlled by a unified control system, reducing the total number of discrete power electronic components needed compared to using separate converter stages for each function.
Solution Approach 2:
The integrated power converter uses universal switching elements that can perform different conversion functions (AC-to-DC and DC-to-DC) depending on the configuration of the switching branches. This multi-functionality reduces the need for specialized components for each converter stage, thereby reducing overall component count and associated cabling requirements.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electronic power converter comprises an AC-to-DC converter stage (105) between an alternating voltage terminal and a direct polarity intermediate circuit (104), and at least two DC-to-DC converter stages (106, 107) connected to the intermediate circuit. The electronic power converter is implemented with modules (108, 109) so that one of the modules constitutes the main circuit of the AC-to-DC converter stage and another module (109) constitutes at least partly the two or more DC-to-DC converter stages. The DC-to-DC converter stages can be used, for example, for controlling the operation of an overvoltage protection resistor and the operation of an energy-storage such as a capacitor or a battery. The implementation of the two or more DC-to-DC converter stages that are needed for different purposes with a single module increases the integration level of the electronic power converter and thereby improves its cost efficiency.