Modular DC-DC Converter Redundancy for Weak-Grid Electrolysis
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Solution Overview
Problem
Existing DC-DC converter devices, particularly those using IGBTs, are prone to failures such as latch-up, dielectric breakdown, and bond wire issues, leading to potential malfunctions and reduced reliability in supplying high-power DC loads like electrolysis plants, especially in weak grids.
Innovation Solution
A modular DC-DC converter device with N submodules in ISOP configuration, a device controller unit, and a redundancy mechanism that enables and disables submodules to provide up to (N-1) times the required power, incorporating galvanically isolated converters to enhance reliability and extend semiconductor lifetime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If IGBTs are used in DC-DC converter devices, then the converter can handle low SCR of weak grids, but the device becomes prone to failures such as latch-up, dielectric breakdown, and bond wire issues
Solution Approach 1:
The converter device is divided into multiple independent submodules (first submodule, second submodule, third submodule) that can operate independently. Each submodule contains its own IGBTs and can be individually disabled if a failure occurs, preventing single-failure disruptions to the entire system.
Solution Approach 2:
The system is designed with redundant submodules and a disability mechanism that activates before complete system failure. When a submodule fails, the controller automatically disables it and redistributes the power load to remaining healthy submodules, cushioning against total system collapse.
2Reliability
If multiple submodules are used in ISOP configuration, then reliability is improved through redundancy, but device complexity increases
Solution Approach 1:
The converter is segmented into identical, standardized submodules connected in ISOP (Input Series-Output Parallel) configuration. Each submodule has the same structure and can be independently controlled, making the complexity manageable through modular design while achieving N-1 redundancy.
Solution Approach 2:
Each submodule is designed as a universal, multi-functional unit that can operate independently or in combination with other submodules. The standardized design allows any submodule to replace any other, simplifying the control logic despite the increased number of components.
3Duration of action of stationary object
If submodules are individually enabled and disabled, then stress on semiconductors is reduced extending lifetime, but control complexity increases
Solution Approach 1:
The controller periodically monitors the operational status and stress levels of each submodule, enabling and disabling submodules in a rotating manner. This periodic action distributes cumulative stress evenly across all submodules, extending their operational lifetime while maintaining manageable control through systematic rotation.
Solution Approach 2:
The control unit continuously monitors the operational status of each submodule and uses this feedback to dynamically enable or disable submodules. This feedback mechanism allows the system to adjust submodule activation based on real-time conditions, distributing stress evenly and extending component lifetime.
Data Source
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AI summary
A modular DC-DC converter device 100, comprises an input interface 102a, 102b, an output interface 104a, 104b, a plurality of N submodules 108, 110, 112, 114, 116, 118 of DC-DC converters connected in ISOP-configuration, each submodule 108, 110, 112, 114, 116, 118 capable of providing an essentially identical amount of submodule DC power, and a device controller unit 120 configured to individually enable and disable provision of submodule DC power of the submodules 108, 110, 112, 114, 116, 118, wherein the DC-DC converter device 100 is configured to supply a DC load 122 connected to the output interface 104a, 104b and requiring an operational DC power of up to (N-1) times the submodule DC power with the required operational DC power while provision of submodule DC power of at least one of the submodules 108, 110, 112, 114, 116, 118 is disabled by the device controller unit 120.