Modular Power Converter Segmentation for Voltage Precision
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Solution Overview
Problem
Conventional power converters for small and medium power applications are inefficient due to high costs, complex electronics, and the need for a large number of modules to achieve finely stepped voltage curves, which is not economically viable for low outputs.
Innovation Solution
A modular power converter with a main module actively supplied by a direct voltage source and additional modules connected in series, allowing adjustable voltage contributions from each module, enabling a small number of modules to achieve a wide range of output voltages through stepped voltage contributions according to powers of two, with the option for inverted operation to recharge storage devices and maintain voltage ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional power converters use a large number of modules to achieve finely stepped voltage curves, then voltage control precision is improved, but device complexity and costs increase significantly
Solution Approach 1:
The power converter is divided into a small number of modular units, each capable of independent voltage contribution. The main module is actively supplied while additional modules are connected in series, allowing each to contribute to the total output voltage independently. This segmentation enables fine voltage stepping with fewer modules compared to conventional approaches.
Solution Approach 2:
The power converter employs dynamic switching of modules between active and inactive states to achieve variable voltage output. The main module can be switched between actively supplied and inactive states, while additional modules can be dynamically connected or disconnected from the series circuit, enabling flexible voltage control without requiring a large fixed number of modules.
2Adaptability or versatility
If conventional power converters use many modules for small and medium power applications, then voltage range is improved, but costs and component complexity increase making it economically unviable
Solution Approach 1:
The additional modules are designed with multi-functionality, serving both as voltage contributors when activated and as rechargeable energy storage when inactive. The same hardware configuration supports both small and medium power applications by dynamically activating only the necessary number of modules, eliminating the need for different converter designs for different power levels.
Solution Approach 2:
The power converter changes its operational parameters by dynamically adjusting the number of actively contributing modules based on the required output power and voltage level. For small power demands, only the main module is actively supplied; for medium power demands, additional modules are activated. This parameter adjustment enables a single converter design to serve multiple power application ranges economically.
3Adaptability or versatility
If power converters use series connection of modules with adjustable voltage contributions, then output voltage flexibility is improved, but control complexity increases
Solution Approach 1:
The additional modules are pre-charged to specific voltage levels before being connected in series with the main module. This preliminary charging action ensures that when modules are activated, they immediately contribute the required voltage without requiring complex real-time voltage regulation, thereby reducing control complexity while maintaining output flexibility.
Solution Approach 2:
The additional modules are equipped with self-charging capability through the inverted operation mode, where they can recharge their internal storage devices using the power converter's own output. This self-service mechanism eliminates the need for external charging infrastructure and reduces the control burden on the main controller, as modules can autonomously maintain their voltage levels.
4Adaptability or versatility
If power converters enable inverted operation for recharging storage devices, then operational flexibility is improved, but switching complexity increases
Solution Approach 1:
The inverted operation for recharging is implemented as a periodic action rather than a continuous function. Additional modules are switched to inverted operation at specific intervals or under specific conditions (such as when their charge level drops below a threshold) to recharge their storage devices. This periodic switching approach reduces the overall switching complexity compared to continuous bidirectional control.
Solution Approach 2:
The main module acts as an intermediary that facilitates the inverted operation of additional modules. When additional modules need recharging, the main module temporarily assumes the role of supplying power back through the series connection to recharge the additional modules' storage devices. This intermediary approach simplifies the switching control compared to direct external charging, as the existing series connection topology is utilized without requiring additional charging circuits.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for efficient, cost-effective generation of finely stepped output voltages with reduced component complexity and lower costs, enabling flexible operation for both small and medium power applications while minimizing the need for extensive filtering.
Implementation Method 1
Each module comprises switching devices and at least one energy storage device, so that the individual module is able to be charged with an adjustable voltage
Data Source
AI summary
The invention relates to a modular power converter which is configured from at least one main module to be actively supplied and an arbitrary number of N−1 further modules. All modules are connected to one another in series (for example by modular terminals, where the term modular terminals shall also comprise any other kind of electrical connection, and in particular plug connections). Each module comprises switching devices and at least one energy storage device, as a result of which the individual module is capable of being charged with an adjustable voltage. The switching devices, which are preferably realized by transistors, allow the module to be connected according to an active operation in terms of the series connection or according to a bypass operation in which case the respective module is quasi bridged and therefore cannot contribute to the voltage path of the series connection. The output voltage of the power converter is tapped at the end points of the series connection.