Modular Converter Power Distribution Using Efficiency Calculations

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Solution Overview

Problem

Conventional power management systems in aircraft are inefficient due to oversized motor controllers that are often underutilized, as they are sized for maximum capacity without considering the efficiency of parallel inverters, leading to increased energy and cost requirements.

Innovation Solution

A modular converter system that dynamically reconfigures combinations of parallel inverters based on predefined efficiency functions to optimize power distribution, selecting combinations that maximize efficiency and minimize power loss, thereby improving utilization and reducing system weight and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple motor controllers are sized for maximum capacity to meet peak power demands, then reliability is improved, but system weight increases

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Multiple motor controllers are merged into a single modular converter system where controllers can operate independently or in parallel. This consolidation reduces total system weight while maintaining the reliability needed for peak power demands through dynamic load sharing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The motor controller system transitions from static, fixed-capacity units to dynamic, reconfigurable modular controllers that can adapt their output based on real-time power demands. This allows the system to provide full power when needed while operating at lower power levels during normal conditions, reducing overall weight requirements.

Inventive Principle:

Principle #15Dynamics

2Power

If multiple motor controllers are sized for maximum capacity to meet peak power demands, then power capacity is improved, but cost increases

Engineering Contradiction:

Improvepower capacityVSAvoidsystem cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

Multiple motor controllers are merged into a single modular converter system where controllers can operate independently or in parallel. This consolidation reduces total system cost while maintaining the power capacity needed for peak demands through dynamic load sharing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The modular motor controllers are designed to perform multiple functions - they can operate individually for standard loads and combine in parallel for peak power demands. This multi-functionality eliminates the need for separate specialized equipment, reducing overall system cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If parallel inverters are operated without efficiency optimization to meet power demand, then power delivery is ensured, but energy consumption increases

Engineering Contradiction:

Improvepower deliveryVSAvoidenergy consumption

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

The controller continuously monitors the operational status and efficiency of each parallel inverter, using this feedback to dynamically adjust which inverters are active and how load is distributed. This ensures power delivery is maintained while minimizing energy consumption by operating inverters in their most efficient ranges.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes operational parameters such as which inverters are active and their individual load assignments based on efficiency calculations. This allows the system to maintain required power delivery while optimizing energy consumption by keeping inverters operating in their high-efficiency zones.

Inventive Principle:

Principle #35Parameter changes

4Use of energy by moving object

If motor controllers are continuously monitored and dynamically reconfigured to optimize efficiency, then energy efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The control system is segmented into modular components that can independently evaluate and control each inverter's operation. This modular approach manages complexity by breaking down the overall control function into smaller, more manageable units while still achieving system-wide efficiency optimization.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3360795B1Power distribution control within a modular converter system using efficiency calculations

Publication Date: 2023.01.04 THE BOEING CO

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AI summary

A method is disclosed for controlling power distribution from a plurality of inverters to one or more loads. The method comprises determining, using one or more computer processors, a plurality of possible combinations of the plurality of inverters to meet load demands corresponding to the one or more loads. Each possible combination of the plurality of possible combinations includes a respective set of one or more inverters of the plurality of inverters. The method further comprises accessing, from a memory coupled with the one or more computer processors, one or more predefined efficiency functions associated with the one or more inverters; selecting, based on the one or more predefined efficiency functions, a combination from the plurality of possible combinations; and transmitting control signals to the set of one or more inverters corresponding to the selected combination to thereby power the one or more loads.