Modular AC-AC Power Supply Using Segmented HF and LF Conversion Stages
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Solution Overview
Problem
Conventional AC-to-AC power supplies in aerospace applications are cumbersome, difficult to customize, and costly due to multiple fixed power conversion stages, making them larger, heavier, and less efficient for varying aircraft requirements.
Innovation Solution
A modular AC to AC frequency conversion apparatus utilizing high frequency (HF) and low frequency (LF) conversion stages with HEMTs and MOSFETs, respectively, allowing for modular design and customization based on application-specific needs, with energy storage capacitors and PWM-controlled switches for efficient frequency conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional multiple power conversion stages are used, then frequency conversion capability is achieved, but device size and weight increase
Solution Approach 1:
The power supply is divided into modular conversion stages, each handling specific frequency conversion tasks. The primary LF stage converts 300Hz to intermediate frequency, while primary HF and secondary LF/HF stages handle additional conversions. This segmentation allows selective activation of stages based on operational needs, reducing overall system weight compared to conventional fixed multi-stage designs.
Solution Approach 2:
The patent implements dynamic stage activation where conversion stages can be selectively enabled or disabled based on operational requirements. The controller dynamically activates only the necessary conversion stages for current frequency conversion needs, allowing the system to adapt its weight footprint to actual operational demands rather than carrying all conversion hardware continuously.
2Speed
If conventional multiple power conversion stages are used, then frequency conversion capability is achieved, but manufacturing cost increases
Solution Approach 1:
The conversion stages are designed with universal components that can serve multiple functions. The same MOSFETs, HEMTs, and control circuitry are used across different conversion stages, allowing a single design to handle various frequency conversion scenarios (300Hz to 60Hz, 300Hz to 400Hz, etc.). This multi-functionality reduces per-unit manufacturing cost compared to conventional dedicated conversion stages.
Solution Approach 2:
The system achieves different frequency conversion ratios by changing operational parameters rather than using physically different conversion circuits. The same hardware infrastructure supports multiple conversion ratios (300:60, 300:400, etc.) through parameter adjustments in control signals and switching sequences, reducing manufacturing complexity and cost.
3Ease of manufacture
If conventional fixed design is used, then initial manufacturing is simplified, but adaptability to different applications decreases
Solution Approach 1:
The power supply uses segmented modular conversion stages that can be independently configured for different applications. Each stage (primary LF, primary HF, secondary LF, secondary HF) can be selectively activated or deactivated based on target application requirements, enabling customization without redesigning the entire system.
Solution Approach 2:
The system employs dynamic configuration capabilities where the controller can adaptively enable or disable specific conversion stages based on real-time operational requirements. This dynamic adaptability allows the same manufactured unit to serve multiple applications (different frequency conversions, different power levels) without physical redesign.
4Speed
If multiple conversion stages are used, then frequency conversion is achieved, but device complexity increases
Solution Approach 1:
The patent merges control functions across multiple conversion stages into a unified control architecture. The controller manages primary LF, primary HF, secondary LF, and secondary HF stages through integrated control logic, reducing the perceived complexity compared to conventional systems where each stage has independent control circuits.
Solution Approach 2:
Universal control circuitry and component designs are used across all conversion stages, allowing the same control hardware and design patterns to manage multiple frequency conversion operations. This universality simplifies the overall system complexity by eliminating the need for dedicated control circuits for each conversion stage.
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 modular design achieves higher efficiency and power density, reducing development costs and improving performance in weight, size, and temperature control by enabling flexible frequency conversion without the need for constant redesign of converter components.
Implementation Method 1
a capacitor configured to store energy of the DC voltage
Data Source
AI summary
An apparatus for modular AC to AC frequency conversion is disclosed. An input AC source is configured to generate an input AC voltage at a first frequency. At least one primary low frequency (LF) conversion stage is configured to generate a DC voltage, and comprises a first pair of metal-oxide-semiconductor field effect transistors (MOSFETs). At least one primary high frequency (HF) conversion stage is configured to generate the DC voltage, and comprises a first pair of high electron mobility transistors (HEMTs). At least one secondary LF conversion stage is configured to receive the DC voltage and generate an output AC voltage at a second frequency, and comprises a second pair of MOSFETs. At least one secondary HF conversion stage is configured to receive the DC voltage and generate the output AC voltage at the second frequency, and comprises a second pair of HEMTs.