Nested Modular Converter for Flexible Energy Interconnection
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Solution Overview
Problem
Conventional electrical converters for AC motors in electric vehicles suffer from low-quality AC voltage generation, high energy losses, electromagnetic compatibility issues, and increased component costs due to peak voltage requirements, as well as limitations in module interconnection flexibility and energy equalization.
Innovation Solution
The development of an electrical converter system with nested modules allows for dynamic parallel and serial connections of energy storage elements, enabling flexible interconnection of non-adjacent modules and reducing the need for high dielectric strength components, while using slower switching elements in higher nesting levels to minimize semiconductor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional bridge circuits are used to convert DC voltage to AC voltage, then the converter can generate AC voltage for AC motors, but the AC voltage quality is low with high distortion and high energy losses occur
Solution Approach 1:
The converter is divided into multiple independent modules, each capable of generating a portion of the output voltage. These modules can be independently controlled and optimized, allowing for higher quality AC voltage generation through pulse width modulation while reducing individual switching losses through distributed operation
Solution Approach 2:
Modules are nested one inside another in a hierarchical structure where outer modules contain inner modules. This nesting enables dynamic reconfiguration of the converter topology, allowing optimal connection arrangements (series, parallel, or hybrid) to be selected based on operating conditions, thereby minimizing energy losses while maintaining high voltage quality
2Productivity
If high-frequency switching is used in conventional converters, then DC to AC conversion is achieved, but electromagnetic compatibility problems arise due to high-energy electromagnetic emissions
Solution Approach 1:
The conversion process is segmented across multiple modules operating at different switching frequencies or phases. This distribution reduces the peak electromagnetic energy emissions from any single switching event while maintaining overall conversion efficiency through coordinated operation of all modules
Solution Approach 2:
The converter employs periodic switching patterns with optimized duty cycles across multiple modules. By distributing switching events periodically across time and modules, the electromagnetic emissions are spread out and reduced in peak intensity, improving electromagnetic compatibility while maintaining productivity
3Reliability
If components are designed for peak voltage in conventional converters, then reliable AC voltage generation is ensured, but component costs increase
Solution Approach 1:
The nested modular structure allows components in inner modules to operate at lower voltage levels compared to outer modules. This hierarchical voltage distribution enables the use of lower-cost components rated for their specific operating voltages rather than requiring all components to be designed for peak system voltage, reducing overall component costs while maintaining reliability
Solution Approach 2:
Each module is designed with components optimized for its specific operating conditions and voltage level. This localized optimization allows components to be selected and designed for their actual operating requirements rather than worst-case peak voltages, reducing component costs while ensuring reliability under normal operating conditions
4Adaptability or versatility
If modules are connected in fixed neighboring relationships in modular converters, then dynamic voltage control is achieved, but interconnection flexibility is limited and ohmic losses increase
Solution Approach 1:
The nested hierarchical structure enables any module to be electrically connected to any other module regardless of physical proximity. Outer modules can access inner modules through defined electrical pathways, allowing flexible reconfiguration of series and parallel connections to minimize ohmic losses for any given operating condition while maintaining high interconnection flexibility
Solution Approach 2:
The converter employs dynamic switching networks that can reconfigure module interconnections in real-time based on operating conditions. This dynamic capability allows the system to optimize connection topology to minimize ohmic losses while maintaining maximum flexibility in module arrangements, overcoming the limitations of fixed neighboring connections
Data Source
AI summary
An electric converter system including modules nested inside one another which have at least two levels of nesting is disclosed. At least one embedded module of a first nesting level is provided, which includes at least two electrical connections and a power train. The power train includes at least two embedded modules nested with each other of an at least second next lower nesting level, such that the modules are embedded inside one another. Each of the modules has switching elements for dynamically switching between switch states between at least two modules of a nesting level. A method for providing an electrical converter system is also disclosed.