Reconfigurable Multi-Cell Power Converter for Fault Isolation
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Solution Overview
Problem
Existing power converters with series-connected cells face challenges in fault isolation and voltage stress during cell failures, requiring interruption of converter operation for cell replacement and increased size and weight due to full bus voltage sustenance.
Innovation Solution
A modular, multi-cell power converter with dual-converter cell architecture and dynamic grounding, featuring switching circuitry for independent reconfiguration of cells between series and parallel connections, enabling safe and fast cell replacement without interrupting operation and reducing voltage stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If series cell connection is used to achieve voltage and current sharing, then converter operation can be maintained with higher voltage capability, but fault isolation becomes difficult and requires interruption of operation for cell replacement
Solution Approach 1:
The patent implements dynamic reconfiguration capability that allows the cell connection topology to switch between series and parallel configurations based on operational needs and fault conditions. This dynamic switching enables the system to maintain series connection for voltage sharing during normal operation, then transition to parallel connection for fault isolation and cell replacement without interrupting converter operation.
2Ease of manufacture
If cells are configured to sustain full bus voltage for safety and grounding, then grounding is simplified and fault detection is easier, but size and weight of the converter increase
Solution Approach 1:
The patent changes the voltage parameter that cells must sustain by introducing dynamic grounding and reconfiguration capability. Instead of cells always sustaining full bus voltage to ground, the system dynamically adjusts grounding references and connection topologies, allowing cells to operate at lower voltage potentials during certain conditions while maintaining safety and fault detection capabilities.
3Ease of operation
If mechanical arrangement with grounded cases is used for simple assembly, then installation and replacement is simplified, but each cell must sustain full bus voltage increasing size and weight
Solution Approach 1:
The patent introduces dynamic reconfiguration capability that allows the system to change connection topologies between series and parallel configurations. This dynamic approach maintains the simplicity of mechanical assembly with grounded cases while reducing the voltage stress on individual cells during parallel operation, thereby decreasing the required insulation distance and overall converter volume.
Data Source
AI summary
A reconfigurable multi-cell power converter and method wherein a set of cells are connected between an input bus and a load in an input series output parallel configuration or in an input parallel output series configuration. Each cell includes a primary side reconfigurable between series and parallel operation and a secondary side also reconfigurable between series and parallel operation. Switching circuitry is configured to reconfigure the primary side of each cell between series and parallel operation and vice versa and also to reconfigure the secondary side of each cell between series and parallel operation and vice versa. A controller is configured to actuate the switching circuitry depending a voltage on the input bus and/or cell condition to reconfigure all the cell primary sides and/or secondary sides while maintaining a desired input series output parallel or input parallel output series connection for the set of cells.