Modular Plug-in Converter for AC-DC Grid Coupling
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Solution Overview
Problem
Existing plug-in converters for exchanging power between AC and DC grid sections lack efficiency and maintenance convenience, with complex configurations and limited modular replacement capabilities.
Innovation Solution
A plug-in converter design featuring modular branch modules housed in isolated containers, allowing easy replacement and maintenance, with a converter unit comprising multiple branches with controllable voltage sources and impedance, enabling efficient power transfer and control between AC and DC grid sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If power modules are arranged in isolated housings within a common housing, then maintenance efficiency is improved and downtime is reduced, but device complexity increases due to modular structure
Solution Approach 1:
The converter is divided into multiple independent branch modules, each containing power modules in isolated housings. This segmentation allows individual modules to be replaced without affecting the entire system, improving maintenance efficiency while the standardized modular design actually reduces overall complexity through repeatability.
Solution Approach 2:
Power modules are extracted from the common housing and placed in isolated housings that can be independently removed and replaced. This extraction enables quick replacement of faulty modules at the site while the removed module can be repaired separately, reducing downtime.
2Ease of repair
If branch modules are designed for easy replacement, then ease of repair is improved, but manufacturing complexity increases
Solution Approach 1:
The converter is divided into standardized branch modules with uniform interfaces and mounting structures. This segmentation enables easy replacement at the site while the standardized design actually simplifies manufacturing through repeatability and modular production techniques.
Solution Approach 2:
Branch modules are designed with universal interfaces and standardized dimensions, allowing the same module design to serve multiple converter units. This universality improves ease of repair through interchangeability while reducing manufacturing complexity through economies of scale and standardized production processes.
3Power
If converter units are configured with multiple converter branches for efficient power exchange, then power transfer capability is improved, but device complexity increases
Solution Approach 1:
The power transfer capability is enhanced by configuring multiple converter branches in parallel, with each branch containing standardized power modules. This segmentation allows power capacity to be scaled by adding branches while maintaining manageable complexity through modular standardization.
Solution Approach 2:
Multiple converter branches are combined within a common housing structure that provides shared support, cooling, and control infrastructure. This merging approach increases power transfer capability while reducing overall complexity by consolidating common functions rather than duplicating them across branches.
Data Source
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AI summary
A plug-in converter for coupling an AC grid section and a DC grid section of a grid system is provided. The plug-in converter (100) comprises a first interface (101) coupled to the AC grid section and a second interface (102) coupled to the DC grid section. The plug-in converter furthermore comprises a converter unit for converting AC in DC voltage or DC in AC voltage. The converter unit comprises a plurality of converter branches (110) (in particular two branches for each AC phase) each having at least two branch modules (120) coupled in series. Each branch module (120) comprises at least one power module (120) having at least one controllable voltage source and at least one impedance (122). Each branch module (120) is arranged in a common first housing (400), in particular a container. Each power module (120) is arranged in a second housing (410), in particular an isolated housing, which is arranged within the common housing (400). As each branch module is arranged in a common housing like a container, such a branch module can be easily exchanged if a fault has occurred within the branch module and can be replaced by a new branch module. The faulty branch module can then be tested and repaired within the factory.