Method for paralleling of interleaved power converters
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Solution Overview
Problem
Interleaved multi-leg power converters face challenges with high current ratings in common components, leading to manufacturing difficulties and regulatory issues due to large components required for high current handling, which complicates troubleshooting and certification.
Innovation Solution
The implementation of a power-conversion system with parallel and interleaved converter legs, where each leg has individual components like relays, fuses, and filters, with a controller to balance current differences between legs, reducing the current conducted by components and enabling smaller, more manageable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If common components are used for high current handling in interleaved multi-leg power converters, then the current handling capability is improved, but the component size increases and manufacturing becomes difficult
Solution Approach 1:
The patent divides the common current path into multiple separate paths by providing individual relays and fuses for each converter leg. This segmentation allows each component to handle only the current of its specific leg rather than the total combined current, reducing component size and manufacturing complexity while maintaining overall high current handling capability
2Power
If common components are used for high current handling, then the power conversion capability is improved, but the component size and regulatory certification difficulty increase
Solution Approach 1:
By segmenting the protection components (relays, fuses) into individual units for each leg, the patent reduces the current rating requirements for each component. This results in smaller, more manageable component sizes that are easier to certify with UL and other regulatory standards, while the overall system maintains high power conversion capability through the combined parallel legs
3Ease of manufacture
If individual components are provided for each converter leg, then the component size is reduced and ease of manufacture is improved, but the system complexity increases
Solution Approach 1:
The patent uses segmentation to provide individual relays and fuses for each converter leg, which simplifies manufacturing by allowing standard smaller components to be used. The system complexity increase is managed through a centralized controller that coordinates the individual legs, and the modular segmented structure actually improves maintainability and troubleshooting compared to a single complex common-component system
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 current rating of components, allowing for smaller, more practical PCB-mounted components and easier UL certification by distributing current effectively between legs, enhancing power density and reducing clearing energy risks.
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.