Inverter Voltage Boost Control for High-Load Waveform Stability

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Solution Overview

Problem

Existing power converters face challenges in maintaining sufficient output voltage across their entire operating range, particularly when loads increase, leading to voltage drops and distorted output waveforms.

Innovation Solution

A voltage boost module is introduced that determines a modulation index based on the DC voltage and target output voltage of the inverter. It assesses whether the target output voltage is within a voltage boost region and adjusts either the target output voltage or its phase angle using an adjustment value, derived from a lookup table or function, to ensure effective voltage production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the inverter operates at high load conditions, then the output power is sufficient, but the output voltage drops and waveform distortion increases

Engineering Contradiction:
Improveoutput powerVSAvoidoutput voltage quality
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The control system performs preliminary assessment of the operating point relative to the voltage boost region boundary before actual inversion occurs. By calculating the modulation index and comparing it with the boundary value in advance, the system proactively determines whether voltage boost is needed, allowing preventive control actions to be taken before voltage drops and distortion occur

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the inverter's operating parameters based on real-time conditions. When the modulation index indicates operation in the voltage boost region, the control system dynamically modifies the output voltage and/or phase angle to maintain optimal performance, transitioning between different control modes as operating conditions change

Inventive Principle:
Principle #15Dynamics

2Reliability

If the modulation index is increased to boost voltage, then the output voltage is sufficient, but the operating point moves into the voltage boost region causing distortion

Engineering Contradiction:
Improveoutput voltage levelVSAvoidwaveform quality
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The control system continuously monitors the modulation index and compares it against the voltage boost region boundary. This feedback mechanism allows the system to detect when operating conditions approach problematic regions and adjust control parameters accordingly, maintaining waveform quality while ensuring sufficient output voltage

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system changes operating parameters (output voltage magnitude and phase angle) based on the assessed operating region. By adjusting these parameters dynamically according to the modulation index and load conditions, the system maintains optimal waveform quality across different operating points

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS20250030352A1Voltage boost module for a power converter
Publication Date: 2025.01.23 EATON INTELLIGENT POWER LTD
  • US20250030352A1 patent drawing
  • US20250030352A1 patent drawing
  • US20250030352A1 patent drawing

AI summary

In one aspect, a power converter includes: an energy storage apparatus; an inverter electrically coupled to the energy storage apparatus; and a voltage boost system configured to: determine a modulation index based on a DC voltage of the energy storage apparatus and a target output voltage of the inverter; and determine whether the target output voltage is in a voltage boost region based on the modulation index; if the target output voltage is in the voltage boost region: determine an adjustment value based on the modulation index; and adjust one or more of the target output voltage and an associated output voltage phase angle based on the adjustment value.