Multi-Function Power Converter for Single-Stage Battery Charging
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Solution Overview
Problem
Existing solar energy systems with storage batteries face inefficiencies in battery charging due to two-stage power conversions, limited high-power charging capabilities, and lack of optimal energy management, leading to suboptimal solar energy usage and increased grid power consumption.
Innovation Solution
A solar energy conversion system with a built-in high-power storage battery charger/discharger and Multi-Function Power Conversion System (MFPCS) that includes four operation switches, LCL filters, multiple DC inductors, and five operation modes, utilizing a three-phase Insulated Gate Bipolar Transistor (IGBT) module and advanced control algorithms for efficient power conversion and battery management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two-stage power conversion (DC-AC and AC-DC) is used for battery charging, then system compatibility with grid-tied architecture is improved, but battery charging efficiency deteriorates
Solution Approach 1:
The patent extracts the battery charging function from the traditional two-stage conversion path and implements it as a direct DC-DC conversion pathway. The MFPCS includes a dedicated battery charging converter that directly converts solar DC power to battery charging current, bypassing the AC grid interface entirely for charging operations, thus eliminating the efficiency loss from double conversion while maintaining system compatibility.
Solution Approach 2:
The MFPCS is designed as a multi-functional power conversion system that can operate in multiple modes: grid-tied inversion, battery charging, and hybrid operation. The same power conversion platform serves both grid connection functions and direct battery charging functions, providing adaptability while enabling efficient single-stage charging when needed.
2Ease of manufacture
If low power battery charger is used to reduce cost, then system cost is reduced, but battery charging time increases
Solution Approach 1:
The patent implements dynamic power adjustment capability in the MFPCS, allowing the battery charging power to vary from low to high levels based on real-time conditions such as solar availability, battery state of charge, and grid status. This dynamic operation enables the system to achieve high-power charging quickly when conditions permit, reducing charging time without requiring a permanently oversized (and expensive) charger.
3Power
If separate high power battery charger is installed to reduce charging time, then battery charging speed is improved, but system cost increases
Solution Approach 1:
The patent merges the battery charging converter with the grid-tied inverter into a single integrated MFPCS. This consolidation allows the system to share common components such as DC-link capacitors, control circuits, and power semiconductor devices, achieving high-power battery charging capability without the additional cost of a completely separate high-power charger system.
4Device complexity
If fixed power conversion architecture is used to simplify design, then device complexity is reduced, but adaptability to varying load power deteriorates
Solution Approach 1:
The MFPCS employs dynamic control strategies that adjust power conversion parameters in real-time based on load demands, solar input variations, and battery state. The control system can dynamically switch between different operating modes and adjust power flow distribution, providing high adaptability to varying load power while maintaining a relatively standardized hardware architecture.
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
The system achieves high-power, single-stage battery charging and discharging, maximizing solar energy usage, reducing grid power consumption, and optimizing energy management to extend peak sun hours.
Implementation Method 1
a three-phase Insulated Gate Bipolar Transistor (IGBT) module mounted on a liquid cooled heatsink
Implementation Method 2
LCL filters plus a transformer
Implementation Method 3
a solar power source
Implementation Method 4
a storage battery power source
Data Source
AI summary
A solar energy system utilizing a Multi-Function Power Converter System (MFPCS) with a solar energy extension control method can be operated as both solar energy converter system and high power battery charger/discharger system, such as an interleaved multi-phase DC/DC converter, or a three-phase grid-tied inverter plus direct battery charger, or a three-phase grid-tied inverter, or a three-phase solar/battery power discharger, or a three-phase PWM rectifier battery charger.