Power Converter Commutation Path for Low-Loss High-Power Conversion
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Solution Overview
Problem
High-efficiency and cost-effective power conversion for high-power applications, such as air-conditioning compressors, is hindered by high costs and crystal defects in large-current-capacity devices, making widespread adoption challenging.
Innovation Solution
A power converter design incorporating voltage varying, commutating, and current smoothing means, along with control mechanisms, to reduce losses and noise, and enhance reliability by commutating current through a secondary path, utilizing wide band gap semiconductor devices like silicon carbide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large-current-capacity semiconductor devices are used for high-power conversion, then power conversion capability is improved, but device cost and manufacturing difficulty increase due to high costs and crystal defects
Solution Approach 1:
The patent divides the current path into multiple segments by introducing a parallel current path with switching devices. Instead of relying on a single large-current-capacity device, the current is segmented and distributed across multiple paths, allowing the use of smaller, more manufacturable devices while achieving the same total power conversion capability.
Solution Approach 2:
The patent introduces switching devices as intermediary elements that control current distribution between parallel paths. These switching devices enable flexible current routing, allowing the system to achieve high power conversion capability without requiring large-current-capacity semiconductor devices directly, thereby reducing manufacturing difficulty and cost.
2Loss of energy
If conventional power converter design is used, then device simplicity is maintained, but energy loss increases due to higher conduction and recovery losses
Solution Approach 1:
The patent segments the current path into multiple parallel paths with switching devices, enabling selective current routing. This segmentation reduces the current burden on individual devices, lowering conduction losses and recovery losses while maintaining a relatively simple overall converter structure through modular design.
Solution Approach 2:
The patent introduces dynamically controllable switching devices that can adjust current distribution in real-time based on operating conditions. This dynamic control optimizes energy efficiency by directing current through the most efficient path under different conditions, reducing overall energy losses while adding only minimal complexity through control circuitry.
3Power
If high-current devices are used, then power handling capability is improved, but noise generation increases leading to higher EMC filter requirements and cost
Solution Approach 1:
The patent segments the high current into multiple parallel paths, which reduces the current magnitude through individual devices. This segmentation lowers the noise generation from each device while maintaining the overall power handling capability, thereby reducing EMC filter requirements and associated costs.
Solution Approach 2:
The switching devices act as intermediaries that control current flow timing and distribution. By precisely controlling when current flows through each path, the switching devices reduce simultaneous switching noise and electromagnetic interference, enabling high power handling with reduced noise generation and simpler EMC filtering.
Data Source
AI summary
A power converter includes step-up means for varying a voltage applied by a power supply to a predetermined voltage, commutating means for performing a commutation operation for allowing a current flowing through the step-up means to flow through a second path, smoothing means for smoothing a voltage related to outputs of the step-up means and the commutating means to produce power and supplying the power to a load side, and control means for performing control related to voltage varying, such as stepping up, by the step-up means and controlling the commutation operation of the commutating means on the basis of at least one of a voltage and a current related to the step-up means.