Power Module Failover Control for Master Module Failure

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Solution Overview

Problem

Existing adaptive modular power conversion systems face significant adverse impacts when the master control module fails, necessitating costly and complex redundant setups to maintain system stability.

Innovation Solution

A control system architecture that migrates control functions from a failed master control module to a designated power module, using a sequential addressing scheme and information tables to ensure seamless operation without requiring redundant modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a redundant master control module is configured to take over when the master control module fails, then system reliability is improved, but device complexity and cost increase significantly

Engineering Contradiction:
Improvesystem reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system implements self-service through automatic master control module election among power modules. When the master control module fails, power modules automatically detect the failure and elect a new master control module without requiring redundant hardware or complex manual intervention, thereby maintaining reliability while reducing system complexity

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

Power modules are designed with multi-functionality, capable of operating both as slave devices under normal conditions and as master control modules when needed. This universal design eliminates the need for dedicated redundant master control modules, reducing device complexity while ensuring system reliability through automatic failover

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If a redundant master control module is configured to take over when the master control module fails, then system reliability is improved, but cost increases excessively

Engineering Contradiction:
Improvesystem reliabilityVSAvoidcost
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

Power modules are designed with multi-functionality, capable of operating both as slave devices under normal conditions and as master control modules when needed. This universal design eliminates the need for dedicated redundant master control modules, reducing device complexity while ensuring system reliability through automatic failover

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If the master control module continuously sends normal operation information to power modules, then system stability is maintained, but energy consumption increases

Engineering Contradiction:
Improvesystem stabilityVSAvoidenergy consumption
Core Design Contradiction:
Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The master control module sends normal operation information to power modules at predetermined periodic intervals rather than continuously. This periodic communication maintains system stability by keeping power modules informed of the master's status while significantly reducing energy consumption compared to continuous communication

Inventive Principle:
Principle #19Periodic action

Data Source

PatentUS20250306559A1Control system, master control module, power module and method thereof
Publication Date: 2025.10.02 SCHNEIDER ELECTRIC (CHINA) CO LTD
  • US20250306559A1 patent drawing
  • US20250306559A1 patent drawing
  • US20250306559A1 patent drawing

AI summary

A control system includes a master control module and at least one power module. The master control module sends information indicating that the master control module operates normally to each of the at least one power module at a predetermined period, and performs a control operation for controlling the at least one power module, and a starting power module whose operating address is a predetermined starting address among the at least one power module operates as the master control module based on not receiving the information within the predetermined period, wherein the operating addresses of the at least one power module are ranked according to a sequential order in which the master control module receives requests for the operating addresses by the at least one power module, and starting from the predetermined starting address.