Multipurpose Power Converter for Transport Climate Control
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Solution Overview
Problem
Transport climate control systems face challenges in efficiently converting single-phase AC power to DC power due to high ripple and harmonic issues, requiring large and costly capacitors, which occupy significant space and increase weight, especially in constrained vehicle environments.
Innovation Solution
A multipurpose power converter with a rectifier, switches, and an inductor-capacitor network that can be configured as either a single-phase or three-phase converter, using an active filter to reduce DC-link capacitance and optimize filtering, allowing for reduced physical size and weight while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single-phase AC power conversion is used, then the system can operate with simpler power input requirements, but the DC-link capacitor size must be large (at or about 2.3 millifarad or higher capacitance) to handle the high ripple and harmonic content
Solution Approach 1:
The invention divides the single-phase power conversion function into two separate converters: a first single-phase AC-DC converter and a second single-phase AC-DC converter. Each converter handles a portion of the power conversion, which reduces the ripple and harmonic content on the DC-link compared to a single converter. This segmentation allows for a smaller DC-link capacitor while maintaining stable DC voltage.
Solution Approach 2:
The invention merges two single-phase AC-DC converters into a unified system that shares a common DC-link and control architecture. By combining the output of two converters, the system achieves better ripple cancellation and more stable DC voltage, enabling reduced capacitor size while maintaining adaptability to single-phase power input.
2Adaptability or versatility
If single-phase AC power conversion is used, then the system can operate with simpler power input requirements, but the physical size of the power converter increases due to larger filter components
Solution Approach 1:
By segmenting the power conversion into two smaller converter modules, each with its own input stage, the system achieves better ripple performance without requiring a single oversized converter. This modular segmentation reduces the need for large filter components in any one location, distributing the filtering requirements across both converters.
Solution Approach 2:
The dual-converter architecture is designed to be universal, capable of handling single-phase AC input while sharing a common DC-link and control system. This multi-functionality allows the system to achieve single-phase operation benefits without the penalty of a single large converter, as the two converters work together to provide stable DC output with reduced filtering requirements.
3Adaptability or versatility
If single-phase AC power conversion is used, then the system can operate with simpler power input requirements, but the weight of the power converter increases due to larger capacitors
Solution Approach 1:
Segmenting the power conversion into two converters reduces the capacitance requirement for each converter and the total DC-link capacitor. The segmented architecture distributes the energy storage and filtering functions, allowing for lighter capacitor components while maintaining the ability to handle single-phase AC input with its inherent ripple challenges.
4Adaptability or versatility
If single-phase AC power conversion is used, then the system can operate with simpler power input requirements, but the cost increases due to larger and more expensive capacitor components
Solution Approach 1:
Segmenting the power conversion system into two converters reduces the capacitance value required for the DC-link capacitor compared to a single converter design. This segmentation allows for the use of smaller, less expensive capacitor components while maintaining the ability to handle single-phase AC input, thereby reducing overall manufacturing cost.
5Adaptability or versatility
If single-phase AC power conversion is used, then the system can operate with simpler power input requirements, but the reliability decreases due to the larger capacitor size and associated failure modes
Solution Approach 1:
Segmenting the power conversion into two converters with a shared DC-link reduces the stress on individual capacitor components. By distributing the ripple current and voltage stress across two converters, the reliability of each capacitor improves, and the system becomes more robust against capacitor failure while maintaining single-phase operation capability.
Data Source
AI summary
Methods and systems for controlling a multipurpose power converter for converting power for a transport climate control system are provided. The multipurpose power converter includes a rectifier having a first leg, a second leg, and a third leg. The multipurpose power converter also includes a first switch, a second switch, and an inductor-capacitor network. The first switch and the second switch are connected to the third leg. The inductor-capacitor network is connected to the first switch. When the first switch is on and the second switch is off, the multipurpose power converter is configured as a single-phase AC power converter. When the first switch is off and the second switch is on, the multipurpose power converter is configured as a three-phase AC power converter.