Modular Solid-State AC/AC Power Conversion for LPT Systems
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Solution Overview
Problem
Conventional large-power-transformer (LPT) systems are inflexible, costly, and have long lead times due to their monolithic design, high material costs, and transportation challenges, making them difficult to modify or replace, especially as they reach the end of their service life, which affects energy security and infrastructure resilience.
Innovation Solution
A high-frequency solid-state alternating current (ac/ac) modular power-conversion approach that allows for scalable, durable, and fault-tolerant designs, reducing the need for extensive redesign and minimizing material costs by using modular components and advanced power-electronic converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional large-power-transformer (LPT) systems use a monolithic design, then they provide stable power transformation, but they become inflexible and difficult to modify or replace
Solution Approach 1:
The patent divides the conventional monolithic LPT into multiple modular units, each capable of independent operation. These modules can be selectively activated or deactivated based on power demand, enabling flexible modification and replacement without affecting the entire system. The modular architecture allows individual modules to be upgraded or replaced independently.
Solution Approach 2:
The system employs dynamic configuration capabilities where modular units can be added, removed, or reconfigured based on changing power requirements. This dynamic adaptability allows the system to evolve over time without complete replacement, addressing the inflexibility of conventional monolithic designs.
2Reliability
If conventional LPT systems use high material quality for durability, then they achieve long service life, but material costs increase significantly
Solution Approach 1:
By segmenting the LPT into modular units, the patent enables selective replacement of only those modules that have reached end-of-life or require maintenance, rather than replacing the entire transformer. This significantly reduces material consumption and costs while maintaining system reliability through continued operation of functional modules.
Solution Approach 2:
The modular design facilitates easier recovery and recycling of materials from individual modules that are removed from service. Valuable materials such as copper and electrical steel can be recovered from specific modules rather than requiring complete system decommissioning, reducing overall material costs.
3Power
If conventional LPT systems are designed for high power capacity, then they meet energy transmission demands, but their size and weight increase, creating transportation challenges
Solution Approach 1:
The patent divides the high-power LPT into multiple smaller modular units, each with reduced individual weight and size. These modules can be transported using standard infrastructure without requiring special transportation arrangements, while collectively delivering the required total power capacity when operated in parallel.
Solution Approach 2:
The modular approach enables power scaling through horizontal addition of modules rather than vertical enlargement of a single unit. This dimensional shift from increasing size of one transformer to adding multiple smaller units resolves the transportation constraint while maintaining high power capacity.
4Reliability
If conventional LPT procurement follows traditional manufacturing processes, then they ensure quality control, but lead times extend beyond 20 months
Solution Approach 1:
The patent enables procurement of standardized modular units that can be manufactured using streamlined processes compared to custom monolithic transformers. These modules can be produced in advance and stored as spare parts, significantly reducing lead times for deployment while maintaining quality through standardized manufacturing procedures.
Solution Approach 2:
The modular design allows for preliminary manufacturing and stocking of spare modules before they are needed. Standardized modules can be produced in advance and kept in inventory, enabling rapid deployment when new capacity is required or when modules need replacement, reducing the 20+ month lead time to a fraction of that duration.
5Reliability
If conventional LPT systems are replaced as they reach end of service life, then energy security is maintained, but the cost and complexity of replacement increase
Solution Approach 1:
The patent enables replacement of only individual modular units rather than entire LPT systems. When modules reach end-of-life, only those specific modules need to be replaced while the rest of the system continues operating. This segmented replacement approach maintains energy security with significantly reduced complexity and cost compared to complete system replacement.
Solution Approach 2:
The modular design creates universal, interchangeable units that can be deployed in multiple configurations and locations. Spare modules can be used across different installations, simplifying replacement operations and reducing the need for location-specific custom parts, thereby reducing replacement complexity while maintaining energy security.
Data Source
AI summary
Aspects of the invention overcome a monolithic approach to conventional low-frequency LPTs by using a high-frequency solid-state alternating current ac/ac modular power-conversion approach. Embodiments of the invention enable the ability to incorporate new technologies without in all cases redoing a LPT design from scratch. Furthermore, given that LPTs are for the long term, aspects of the invention ensure that they are durable, efficient, and fault tolerant with overloading capability.