Interleaved UPS Converter Legs for Current Balancing and Smaller Components
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Solution Overview
Problem
Current multi-leg power converters face challenges with high current ratings in common components, leading to manufacturing difficulties and regulatory compliance issues due to large, high-current components, which complicate troubleshooting and certification.
Innovation Solution
The design incorporates two interleaved converter legs with individual components, including relays, fuses, and filters, where each leg conducts only its share of the current, allowing for reduced current ratings and inductive coupling between legs to share ripple currents, with a controller managing current differences to balance the legs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If common components are used for multiple converter legs, then device complexity is reduced, but the current rating of common components increases leading to manufacturing difficulties and regulatory compliance issues
Solution Approach 1:
The patent segments the common components (relays, fuses, filters) into individual components for each converter leg. Instead of using shared components that must handle total system current, each leg has its own relay, fuse, and filter components that only handle the current for that specific leg. This segmentation reduces the current rating requirements for each component, making them easier to manufacture and comply with regulatory standards.
2Device complexity
If common components are used for multiple converter legs, then device complexity is reduced, but component size increases due to high current ratings
Solution Approach 1:
The patent segments the common components (relays, fuses, filters) into individual components for each converter leg. Instead of using shared components that must handle total system current, each leg has its own relay, fuse, and filter components that only handle the current for that specific leg. This segmentation reduces the current rating requirements for each component, making them easier to manufacture and comply with regulatory standards.
3Ease of manufacture
If individual components are used for each converter leg, then ease of manufacture is improved and component size is reduced, but device complexity increases
Solution Approach 1:
The patent segments the common components (relays, fuses, filters) into individual components for each converter leg. Instead of using shared components that must handle total system current, each leg has its own relay, fuse, and filter components that only handle the current for that specific leg. This segmentation reduces the current rating requirements for each component, making them easier to manufacture and comply with regulatory standards.
4Weight of moving object
If individual components are used for each converter leg, then component size is reduced, but clearing energy in fuses increases
Solution Approach 1:
The patent segments the common components (relays, fuses, filters) into individual components for each converter leg. Instead of using shared components that must handle total system current, each leg has its own relay, fuse, and filter components that only handle the current for that specific leg. This segmentation reduces the current rating requirements for each component, making them easier to manufacture and comply with regulatory standards.
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 approach reduces the size and complexity of converter components, enhances power density, and simplifies compliance with regulatory standards by reducing the current conducted by each component and minimizing clearing energy in fuses.
Implementation Method 1
the first choke is configured to induce, responsive to a first ripple current passing through the first converter leg, a first induced current in the second choke, and the second choke is configured to induce, responsive to a second ripple current passing through the second converter leg, a second induced current in the first choke
Data Source
AI summary
Examples of the disclosure include a UPS comprising an output to be coupled to a load, a first converter leg to provide a first voltage to the output and including at least one of a first relay or fuse, a second converter leg in parallel with the first converter leg including at least one of a second relay or fuse and configured to provide a second voltage to the output out of phase with the first converter leg providing the first voltage signal, current sensors coupled to the first and second converter legs, respectively, and configured to provide a first signal indicative of a current in the first converter leg and a second signal indicative of a current in the second converter leg, respectively, and at least one controller to receive the signals, determine a current difference between the converter legs based on the signals, and decrease the current difference.