Power Converter Control System Serial Communication Timing
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Solution Overview
Problem
Current power converter control systems face challenges in transmitting switching control signals with high timing precision and low latency across distributed converter modules, particularly in high-power applications, due to limitations in communication link flexibility and bandwidth, which can lead to inflexible circuitry and reduced response times to errors.
Innovation Solution
A method and control system that utilize serial communication links with cycle times equal to or less than the shortest time constant of the converter module, allowing for radial communication architecture, full-duplex data transmission, and error correction mechanisms like majority voting and CRC-checks to ensure precise switching control and fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If parallel communication links are used to transmit switching control signals to distributed converter modules, then bandwidth and data transmission capacity are improved, but device complexity and circuitry requirements increase significantly
Solution Approach 1:
The patent segments the control system into a master controller that generates control messages and multiple slave controllers that receive and execute them. Each slave controller operates independently with its own converter module, allowing control signals to be transmitted sequentially rather than requiring simultaneous parallel connections. This segmentation reduces the need for complex parallel communication circuitry while maintaining effective control of all converter modules.
2Loss of time
If the communication cycle time is reduced to improve response speed, then latency and error response time are improved, but the complexity of timing synchronization increases
Solution Approach 1:
The patent merges the timing reference function into the control message itself. The master controller includes a timing reference in each control message that all slave controllers use to synchronize their operations. This approach allows for reduced cycle times and improved response latency without requiring separate complex timing synchronization circuits, as the timing information is carried within the existing control communication infrastructure.
3Power
If more converter modules are connected in parallel to increase power capacity, then power conversion capability is improved, but the number of communication links and control signals required increases
Solution Approach 1:
The patent implements a universal control message format that can be used to control any number of converter modules. The control message structure is designed to be multi-functional, accommodating different slave controllers and converter module configurations without requiring different communication protocols or additional dedicated control signals for each module. This allows power conversion capability to be scaled by adding parallel modules while maintaining a consistent, manageable communication architecture.
Data Source
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AI summary
A control system for controlling conversion of an input power into an output power in at least one converter module (27) comprising at least one input power terminal, at least one output power terminal, and for each output power terminal at least one active switching device (35) connected between the an input power terminal and the respective output power terminal, by controlling the timing of the switching of the at least one active switching device (35) is provided. The control system comprises a master controller (33) and, for each converter module controlled by the master controller (33), a communication link (40) interconnecting the master controller (33) and the respective converter module (27). In addition, it comprises a timing generator (45) generating a timing signal having a cycle time equal to or less than the shortest time constant of the converter modules (27) and the immediate power circuit elements relating to the used respective converter module. The timing generator (45) is integrated in or interconnected with the master controller (33). Furthermore, the control system comprises a signal generator (46) being integrated in or interconnected with the master controller (33) which generates switching control signals, each switching control signal containing a control message defining a switching state for the at least one active switching device (35) in a converter module (27) interconnected with the master controller (33), the duration of each control message being equal to or less than the cycle time. The communication links (40) are serial communication links.