Voltage conversion system for transport refrigeration system
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Solution Overview
Problem
Existing transport refrigeration systems face challenges in designing an efficient, lightweight, and battery-compatible electrical system due to high voltage and low power operation, especially when dealing with varying battery configurations.
Innovation Solution
A voltage conversion system with a non-coupled inductor structure and multiphase boost stage, integrated with an inverter, allows for efficient DC-to-AC power conversion, providing high power density and flexibility to operate with different battery voltages, and includes a compact design with reduced current ripple for enhanced battery life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional electrical system is designed for high voltage and low power operation with wide battery voltage range, then the system must be compatible with different battery configurations, but the system becomes complex and difficult to optimize for efficiency and weight
Solution Approach 1:
The power conversion unit is designed to accept a wide input voltage range (24V to 72V DC) by adjusting operating parameters of the boost converter and control algorithm, enabling compatibility with different battery configurations without requiring multiple dedicated designs. The system dynamically adapts to input voltage variations while maintaining efficient operation across the entire range.
2Power
If a voltage conversion system is designed for high power density, then the system becomes compact and efficient, but the design becomes more challenging and complex
Solution Approach 1:
The power conversion unit integrates the DC-DC boost converter and DC-AC inverter functions into a single unified system with shared control electronics and magnetic components. This consolidation achieves high power density by eliminating redundant components and reducing overall system size, while the modular architecture manages design complexity through systematic integration of functions.
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
The solution provides a high power density, efficient, and flexible voltage conversion system that is compact in size, capable of operating with various battery voltages, enhancing battery life and compatibility with different battery configurations, which is advantageous for transport refrigeration systems.
Implementation Method 1
a power conversion unit connected to the energy storage device, the power conversion unit comprising: an inductor, the inductor comprising a number of coils that are non-coupled or weakly coupled
Implementation Method 2
an inverter coupled to the multiphase boost stage
Data Source
AI summary
A voltage conversion system includes an energy storage device; a power conversion unit connected to the energy storage device, the power conversion unit comprising: an inductor, the inductor comprising a number of coils that are non-coupled or weakly coupled, with a coupling coefficient less than 0.05; a multi-phase boost stage coupled to the inductor, wherein the multiphase boost stage comprises a number of phases that equals the number of coils; an inverter coupled to the multiphase boost stage; and a load coupled to the power conversion unit.