Interleave Power Converter with Load-Adaptive Converter Switching
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Solution Overview
Problem
Conventional power converters for air conditioners face inefficiencies due to switching losses at varying load levels, particularly at low and high loads, where the operation of multiple converters leads to reduced efficiency and increased ripple in input current.
Innovation Solution
A power converter with an interleave converter configuration that adjusts the number of operating converters based on load levels, using a controller to manage switching elements such as MOSFETs and IGBTs, allowing only necessary converters to operate at low loads and performing interleaved operations at high loads to optimize efficiency and reduce ripple.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple converters operate simultaneously in the interleave converter, then the power conversion capacity is increased, but switching losses increase and efficiency decreases at low load levels
Solution Approach 1:
The patent applies dynamics by making the number of operating converters variable rather than fixed. The controller dynamically adjusts the number of active converters based on real-time load detection, transitioning from single converter operation at low loads to multiple converter operation at high loads, thereby optimizing the balance between power capacity and switching losses across different operating conditions
Solution Approach 2:
The patent changes the operational parameter of converter quantity from a static configuration to a dynamic variable. By detecting load levels and adjusting the number of active converters accordingly, the system adapts its power conversion capacity to match actual demand, reducing switching losses when full capacity is not required while maintaining the ability to handle peak loads
2Power
If multiple converters operate simultaneously in the interleave converter, then the power conversion capacity is increased, but efficiency decreases at high load levels due to increased ripple in input current
Solution Approach 1:
The system dynamically adjusts converter operation modes based on load conditions. At high load levels, the controller activates multiple converters in interleaved mode with phase-shifted switching, which distributes the ripple current across multiple phases and reduces the overall input current ripple, thereby maintaining efficiency even at high power conversion capacity
Solution Approach 2:
The patent employs periodic interleaved operation where multiple converters switch in a phased, periodic manner. This periodic action with controlled phase shifts causes the ripple currents from individual converters to cancel each other out partially, reducing the net ripple in the input current and improving overall system efficiency at high load levels
3Device complexity
If a single converter type is used, then the device complexity is reduced, but adaptability to varying load levels is insufficient
Solution Approach 1:
The patent segments the power conversion function into multiple identical converter modules that can be independently controlled. This segmentation allows the system to activate only the necessary number of modules based on load requirements, providing adaptability to varying load levels while maintaining relatively simple individual module designs that reduce overall device complexity
Solution Approach 2:
The patent implements multi-functionality by designing converters with universal switching elements capable of operating in different configurations. The same converter hardware can function in single-converter mode at low loads or in interleaved multi-converter mode at high loads, providing adaptability across the entire load range without requiring completely different device configurations
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 operational efficiency across all load regions, reduces switching losses, and minimizes input current ripple, enabling efficient power conversion for air conditioners with varying loads, such as those in compressors.
Implementation Method 1
a rectifying unit configured to rectify an input AC current
Implementation Method 2
an interleave converter that has a plurality of converters and that is configured to convert rectified output from the rectifying unit to DC power
Data Source
AI summary
A power converter and an air conditioner having the same, in which the power converter includes a rectifying unit configured to rectify an input AC current and an interleave converter that has a plurality of converters and that is configured to convert rectified output from the rectifying unit to DC power and output the converted DC power. The power converter also includes a capacitor connected to an output terminal of the interleave converter, and a converter controller configured to control the interleave converter. The converter controller controls the interleave converter by calculating a load level of both terminals of the capacitor and changing a number of operating converters in the plurality of converters of the interleave converter based on the determined load level of both terminals of the capacitor.