Integrated Resistor and Bypass Housing for Power Converter Pre-Charging
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Solution Overview
Problem
Self-commutated power converters face challenges in pre-charging energy storage devices without causing high inrush currents and unwanted energy losses, particularly in high-voltage applications, where existing solutions require separate gas-tight housings and connecting elements for resistors and bridging devices, leading to increased complexity and costs.
Innovation Solution
A self-commutated power converter design where an electrical resistance and a bridging device are integrated within a single gas-tight housing, filled with insulating gas, allowing for a compact and cost-effective arrangement with a rotating symmetrical housing and insulators that serve both as electrical insulation and holding components, enabling efficient pre-charging and energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resistor and bridging device are arranged in separate gas-tight housings, then each component can be independently protected and maintained, but the device complexity and space requirements increase significantly
Solution Approach 1:
The patent combines the resistor and bridging device into a single common gas-tight housing, eliminating the need for separate housings and connecting elements. This merging approach maintains the protective function while significantly reducing structural complexity and space requirements.
Solution Approach 2:
The common housing serves multiple functions: it provides gas-tight protection for both the resistor and bridging device, eliminates the need for separate connecting elements, and reduces the overall number of components. This multi-functionality resolves the contradiction by achieving protection without increased complexity.
2Reliability
If separate gas-tight housings and connecting elements are used for the resistor and bridging device, then component isolation is maintained, but space and cost requirements increase
Solution Approach 1:
By merging the resistor and bridging device into one common housing, the patent eliminates the space required for separate housings and connecting elements. The compact integrated design maintains functional isolation while reducing overall footprint.
3Reliability
If the resistor is used for pre-charging energy storage devices, then inrush currents are limited, but energy losses occur during converter operation
Solution Approach 1:
The bridging device dynamically changes the circuit configuration by switching the resistor out of the circuit after pre-charging is complete. This dynamic switching allows the system to benefit from the resistor's current-limiting function during startup while eliminating energy losses during normal operation.
Solution Approach 2:
The resistor performs its current-limiting function only during the preliminary pre-charging phase. Once the energy storage device is charged, the bridging device activates to remove the resistor from the circuit, preventing unnecessary energy losses during subsequent operation.
4Loss of energy
If a bridging device is added to short-circuit the resistor after pre-charging, then energy losses are reduced, but device complexity increases
Solution Approach 1:
The bridging device is integrated into the same common housing as the resistor, sharing the same protective enclosure and mounting structure. This integration minimizes the additional complexity introduced by the bridging function while achieving the energy loss reduction benefit.
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 design reduces space and cost requirements by eliminating the need for separate housings and connecting elements, allowing for efficient pre-charging of energy storage devices while minimizing energy losses and maintaining high-voltage integrity.
Implementation Method 1
The housing can be filled with an electrically insulating gas
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an assembly (1) comprising an electric resistor (3) located in a gas-tight housing (13). The housing (13) further accommodates a bypass device (5) for bypassing the resistor (3).