Matrix Converter MPC with Load Current Estimation

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Solution Overview

Problem

Existing matrix converter systems operating in current control mode require costly or bulky current sensors to track output voltage or current, as they do not effectively model or predict load current, limiting their ability to minimize losses.

Innovation Solution

A matrix converter system that uses model predictive control (MPC) to estimate load current without a current sensor, selecting switching states in the switching matrix to minimize errors between output voltage and current references, using a multi-objective function that includes terms for voltage and current errors, and employs an observer to estimate load current.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional control methods are used with current sensors to track output voltage or current, then measurement accuracy is improved, but device cost and complexity increase due to costly or bulky current sensors

Engineering Contradiction:
Improveload current measurement accuracyVSAvoidcurrent sensor requirement
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent creates a mathematical model (copy) of the load current behavior based on the known switching states and circuit parameters. Instead of directly measuring the physical current with sensors, the system uses the electrical circuit model to calculate and predict load current, replacing the need for physical current sensors while maintaining measurement accuracy.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical/electrical current sensing system with an electrical/mathematical modeling system. By substituting physical sensors with computational models that calculate current based on circuit equations and switching states, the system eliminates bulky hardware while achieving the same measurement function.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If model predictive control is implemented without load current information, then device complexity is reduced, but control precision deteriorates due to inability to track output voltage or current effectively

Engineering Contradiction:
Improvecurrent sensor eliminationVSAvoidoutput voltage/current tracking precision
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary calculation of load current using the electrical circuit model before the actual control action is taken. By predicting the load current in advance based on current switching states and circuit parameters, the system has the necessary current information ready for the MPC algorithm, enabling precise control without requiring physical sensors.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements a feedback mechanism where the calculated load current from the electrical circuit model is fed back into the MPC controller. This feedback loop allows the controller to continuously adjust switching states based on the predicted current, maintaining precise tracking of output voltage and current references despite eliminating physical current sensors.

Inventive Principle:
Principle #23Feedback

3Loss of energy

If electrical circuit modeling is used to estimate load current, then loss minimization is improved through better control, but calculation complexity increases due to mathematical modeling requirements

Engineering Contradiction:
Improveconverter lossesVSAvoidmathematical modeling complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent changes the approach from direct physical measurement to mathematical parameter calculation. By using electrical circuit parameters (resistances, inductances, capacitances) and switching states as inputs to calculate load current, the system achieves energy loss minimization through precise control while the computational complexity remains manageable due to the use of standard circuit equations.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentEP3722896B1Model predictive control for matrix converter operating in current control mode with load current estimation
Publication Date: 2023.12.27 HAMILTON SUNDSTRAND CORP
  • EP3722896B1 patent drawingFigure 1
  • EP3722896B1 patent drawingFigure 2
  • EP3722896B1 patent drawingFigure 3

AI summary

A matrix converter system operating in current control mode is provided. The matrix converter (102) includes a switching matrix coupled between a low voltage side and a high voltage side, wherein the matrix converter is coupled at its low voltage side to a generator (104) for receiving an input power including an input current and transforming the input power into an output power at its high voltage side, wherein a load is coupled to the high voltage side. The control system includes a load observer (214) and a model predictive controller (MPC) (212). The load observer is configured to estimate a load current that flows to the load from the high voltage side of the matrix converter as a function of a switching state of the switching matrix, an output voltage output at the high voltage side of the matrix converter, and the input current.. The MPC is configured to select the switching state of the switching matrix to meet one or more control objectives defined by minimization of a multi-objective function that tracks the output voltage and the input current using the estimated load current.