Modular Inverter Platform Physical Electrical Configurability

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Solution Overview

Problem

Existing inverter systems lack the ability to easily adapt to varying power, performance, and packaging needs across different applications, requiring custom-designed components for each specific application, which limits their scalability and configurability.

Innovation Solution

A modular inverter platform with a printed circuit board (PCB) that includes multiple modules and mounting components allowing physical and electrical configurability, enabling switching between various configurations through software, jumpers, or addition/subtraction of circuit elements, such as inductors, capacitors, and transformers, to accommodate different power and voltage requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom-designed components are used for each specific application, then the inverter can meet particular power and performance needs, but the device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveapplication-specific customizationVSAvoidcomponent design variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inverter is divided into separate functional modules (rectifier module, inverter bridge module, filter module, control module, sensor modules, thermal management module) that can be independently designed, manufactured, and configured. This segmentation allows standardization of each module while enabling customization through different module combinations for different applications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates universal module designs with standardized interfaces and mounting mechanisms that can be used across multiple applications. The same basic module architecture serves different power ratings and configurations by varying the number of modules or their interconnection patterns, eliminating the need for completely custom designs for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If application-specific inverter designs are used, then performance requirements are met, but the scalability to different configurations is limited

Engineering Contradiction:

Improveperformance matchingVSAvoidconfiguration scalability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The inverter system incorporates dynamic reconfigurability through selectable mounting components that allow modules to be physically repositioned and electrically reconfigured during installation or maintenance. This enables the system to adapt to different configuration requirements (single-phase, split-phase, three-phase) without requiring custom designs for each scenario.

Inventive Principle:

Principle #15Dynamics

3Productivity

If multiple custom components are used for different applications, then specific power needs are met, but component redundancy and inventory requirements increase

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidcomponent inventory

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

By designing universal modules with standardized interfaces and configurable interconnections, the same physical components can serve multiple applications and configurations. A single module type can be used in single-phase, split-phase, or three-phase configurations by changing the mounting arrangement and electrical interconnections, dramatically reducing the variety of components that need to be inventoried.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If fixed physical configurations are used, then manufacturing is simplified, but the ability to reconfigure for different applications is reduced

Engineering Contradiction:

Improveassembly simplicityVSAvoidphysical configurability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The modular architecture with standardized interfaces simplifies manufacturing of individual modules while enabling complex system configurations through straightforward assembly of standardized components. Each module can be manufactured independently using the same processes, then assembled into different configurations based on application requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates dynamic reconfigurability through selectable mounting components that allow modules to be physically repositioned and electrically reconfigured during installation or maintenance, enabling the same manufactured modules to adapt to different physical configurations as needed.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS9722510B2Modular inverter platform providing physical and electrical configurability and scalability

Publication Date: 2017.08.01 CUMMINS POWER GENERATION IP INC

AI summary

Modular inverter platforms and methods for providing physical and electrical configurability and scalability are disclosed. The modular inverter apparatus includes a printed circuit board (PCB) comprising at least two modules and one or more mounting components structured to switch the at least two modules between a plurality of physical configurations. The modular inverter apparatus also includes a plurality of electrical interconnections structured to electrically connect the at least two modules and to switch the at least two modules between a plurality of electrical configurations.