Power Conversion Device with Three-Stage Layered Structure
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Solution Overview
Problem
The existing power conversion devices for solar power generation face challenges in size reduction due to high voltage insulation requirements, leading to increased size and weight, making it difficult to dispose them close to solar panels, which results in shading issues and increased wiring losses.
Innovation Solution
A power conversion device configuration with a single-phase resonant type converter and multiple power conversion units connected in series, arranged in a three-stage layered structure within a compact housing, allowing for efficient cooling and reduced insulation distances, enabling a low-profile design that can be installed near solar panels, thus minimizing shading and wiring losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-voltage insulation transformer is used for step-up output, then the power conversion device can operate at high voltage, but the device size and weight increase significantly
Solution Approach 1:
The patent divides the power conversion system into multiple independent power conversion units, each handling a portion of the total power. Instead of using one large high-voltage transformer, the system uses multiple smaller transformers or performs power conversion at lower voltage levels in distributed units, thereby reducing the weight of individual components while achieving the required total power output.
Solution Approach 2:
The patent transitions from a single-stage high-voltage power conversion approach to a multi-stage or distributed power conversion architecture. By arranging power conversion units in series or parallel configurations across multiple dimensions (voltage levels, physical locations), the system achieves high-voltage output capability without requiring a single massive transformer, thus reducing overall device weight.
2Ease of operation
If the power conversion device is disposed away from the solar panel, then the device can be installed with adequate space, but wiring losses increase and shading problems occur
Solution Approach 1:
The patent segments the power conversion function into multiple distributed units that can be installed in series along the wiring path between solar panels and the grid. This allows the power conversion devices to be positioned closer to the solar panels in a staggered arrangement, reducing the length of DC wiring and minimizing wiring losses while maintaining adequate installation space for each unit.
3Productivity
If multiple power conversion units are connected in series to form three-phase output, then the power conversion efficiency is improved, but the insulation distance requirements increase the device size
Solution Approach 1:
The patent merges multiple power conversion units into a single integrated housing structure. By combining the insulation measures, cooling systems, and electrical connections of multiple units into one unified device, the system achieves three-phase power conversion with improved efficiency while minimizing the total volume required compared to separate distributed units.
Solution Approach 2:
The patent implements a nested arrangement where power conversion units are housed within a common enclosure with shared insulation barriers and cooling infrastructure. The units are arranged concentrically or in nested layers, allowing efficient use of space while maintaining required insulation distances between high-voltage components, thus reducing overall device volume.
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 achieves size reduction, efficient cooling, and reduced wiring losses, allowing for a more compact and efficient power conversion system that can be installed closer to solar panels, enhancing the overall performance and reliability of solar power generation systems.
Implementation Method 1
a single-phase inverter on a secondary side of a resonant type converter that has an input of a direct current
Implementation Method 2
a first cooling fin that contacts a heat radiating surface of the semiconductor device
Implementation Method 3
a second cooling fin that is positioned opposite to the first cooling fin with a predetermined interval in a state where the semiconductor device is mounted on the circuit board
Data Source
AI summary
In a power conversion device, a power conversion unit includes a single-phase inverter on a secondary side of a resonant type converter that has an input of a direct current. A power conversion unit group is configured by connecting outputs of the single-phase inverters of a plurality of power conversion units in series. Respective phases of three phase alternate current are formed with the three power conversion unit groups housed in a power conversion device housing. The plurality of power conversion units constituting the power conversion unit group are disposed along a longitudinal direction of the power conversion device housing. The respective three power conversion unit groups are disposed at an upper stage, a middle stage, and a lower stage in a height direction of the power conversion device housing. The power conversion device housing has one end side in the longitudinal direction as output terminals of the three power conversion unit groups. The power conversion device housing has the other end side in the longitudinal direction where terminals of the three power conversion unit groups are connected in common.