Class-E Rectifier Capacitor Control for Thermal Runaway Prevention

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Solution Overview

Problem

Conventional class-E rectifier circuits experience a change in capacitance with temperature, leading to increased voltage peak values and decreased impedance, causing over temperature due to thermal runaway.

Innovation Solution

A power conversion device and method that regulate the AC wave input to a rectifier capacitor based on impedance changes, using a detector to monitor impedance and a controller to adjust the drive frequency of the switching element to maintain optimal impedance and prevent over temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the capacitance of the rectifier capacitor decreases due to temperature increase, then the peak value of the voltage waveform increases, but the impedance decreases leading to thermal runaway

Engineering Contradiction:
Improvetemperature of rectifier capacitorVSAvoidimpedance stability
Core Design Contradiction:
TemperatureVSReliability

Solution Approach 1:

The controller monitors the impedance of the rectifier capacitor and adjusts the drive frequency based on the detected impedance value, creating a closed-loop feedback system that maintains stable operation despite temperature variations

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The controller changes the drive frequency parameter in response to impedance changes, thereby compensating for the capacitance variation caused by temperature increases and preventing thermal runaway

Inventive Principle:
Principle #35Parameter changes

2Stability of the object's composition

If the drive frequency is increased to compensate for capacitance decrease, then the voltage peak can be controlled, but switching loss increases

Engineering Contradiction:
Improvevoltage waveform stabilityVSAvoidswitching loss
Core Design Contradiction:
Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The controller dynamically adjusts the drive frequency based on real-time impedance detection, optimizing the balance between voltage stability and switching loss by making frequency changes only when necessary

Inventive Principle:
Principle #15Dynamics

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

The solution effectively suppresses impedance changes in the rectifier capacitor, stabilizing input current, output voltage, and input impedance, thereby preventing over temperature in the rectifier capacitor.

Implementation Method 1

the capacitance value of the capacitor constituting the rectifier circuit changes depending on the temperature characteristics

Methodology Applied
Scientific EffectCapacitance: Capacitance

Implementation Method 2

an alternating-current (AC) wave generation circuit for generating an AC wave

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3944482B1Method for controlling power conversion device, and power conversion device
Publication Date: 2024.01.17 NISSAN MOTOR CO LTD
  • EP3944482B1 patent drawingFigure 1
  • EP3944482B1 patent drawingFigure 2~3
  • EP3944482B1 patent drawingFigure 4~5

AI summary

A method for controlling a power conversion device can prevent over temperature by suppressing a change in impedance of a capacitor included in a rectifier circuit. The power conversion device (1) includes an AC wave generation circuit (5) for generating an AC wave, and a rectifier circuit (7) for rectifying the AC wave generated by the AC wave generation circuit (5) with a configuration including a rectifier capacitor (73) and a diode (71) connected in parallel. The method for controlling the power conversion device (1) regulates the AC wave input to the rectifier capacitor (73) depending on a change in impedance of the rectifier capacitor (73) so as to suppress the change in the impedance of the rectifier capacitor (73).