Parallel AC/DC Converter Modulation for Light-Load Efficiency

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Solution Overview

Problem

Existing power converters exhibit low efficiency, particularly at light power loads due to power consumption by electronic components and issues with circulating currents in parallel configurations.

Innovation Solution

A power converter apparatus with a plurality of single-phase power converting circuits in parallel, where one circuit has a single-stage AC/DC converter and the others have a two-stage converter module, automatically bypassing the output stage DC/DC transformers at low loads to reduce power loss and improve efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If multiple non-isolated converters are connected in parallel, then conversion efficiency is improved, but circulating currents occur which are not desirable

Engineering Contradiction:
Improveconversion efficiencyVSAvoidcirculating currents
Core Design Contradiction:
Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a current sharing controller as an intermediary device that actively manages the parallel-connected non-isolated converters. This controller monitors and regulates the output currents of each converter module, preventing circulating currents while maintaining the efficiency benefits of parallel non-isolated configuration. The controller acts as a mediator that coordinates the operation of multiple converters without requiring isolated transformer connections.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If traditional isolated converters are connected in parallel, then reliability is improved, but power efficiency deteriorates especially at light power load

Engineering Contradiction:
Improvesystem reliabilityVSAvoidpower efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent dynamically changes the operating parameters of the converter system based on load conditions. At light power loads, the system activates only the necessary number of converter modules and adjusts their operating points to maintain high efficiency. The controller modifies duty cycles, switching frequencies, and module activation states according to real-time load requirements, enabling the system to maintain both reliability through redundancy and efficiency through adaptive parameter adjustment.

Inventive Principle:
Principle #35Parameter changes

3Device complexity

If driving power and capacitive loss of electronic components are irrespective of load power, then device complexity is reduced, but conversion efficiency deteriorates at light power load

Engineering Contradiction:
Improvecontrol circuit complexityVSAvoidconversion efficiency
Core Design Contradiction:
Device complexityVSLoss of energy

Solution Approach 1:

The patent implements dynamic adaptation of the converter system configuration based on load power levels. The controller dynamically adjusts the number of active converter modules, their connection topology, and operating parameters according to real-time load conditions. At light loads, fewer modules are activated and the system operates in a simplified configuration to minimize fixed power losses. As load increases, more modules are engaged to maintain efficiency. This dynamic reconfiguration allows the system to overcome the fixed power consumption of control circuits and capacitors that would otherwise dominate at light loads.

Inventive Principle:
Principle #15Dynamics

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 enhances power conversion efficiency by adapting the number of operating phases based on load power, achieving efficiencies greater than 98% in single-phase operation and increasing efficiency by 5-13% compared to conventional systems at light loads.

Implementation Method 1

a power converter apparatus for converting an alternating current (AC) power input to a direct current (DC) power output

Methodology Applied
Scientific EffectElectromagnetic transformation: Electromagnetic Induction

Implementation Method 2

each of remaining n−1 second single-phase power converting circuits comprises a two-stage converter module having an AC/DC converter as an input stage and a DC/DC transformer as an output stage

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11843322B2Power converter apparatus and a method of modulating thereof
Publication Date: 2023.12.12 HONG KONG APPLIED SCI & TECH RES INST
  • US11843322B2 patent drawing
  • US11843322B2 patent drawing
  • US11843322B2 patent drawing

AI summary

The invention provides a power converter apparatus for converting an alternating current (AC) power input to a direct current (DC) power output. The apparatus comprises a plurality of n single-phase power converting circuits arranged in parallel, where n is equal to or greater than 2, wherein one of said n single-phase power converting circuits comprises a single-stage AC/DC converter module having an operating AC/DC converter; and each of a remaining n−1 of said single-phase power converting circuits comprises a two-stage converter module having an AC/DC converter as an input stage and a DC/DC transformer as an output stage.