Series-Parallel Converter Topology for 400V-800V Voltage Range
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Solution Overview
Problem
Existing power modules struggle to efficiently convert a wide range of input voltages, particularly when operating between 400 V and 800 V, due to challenges in designing magnetic elements that cover the entire voltage range with a single converter.
Innovation Solution
A converter system comprising first and second converters connected in series or parallel by a switching unit, controlled by a control unit to adapt to different input voltages, and a power module with additional converters and switching units to handle varying input and output voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single converter is designed to cover the entire 400V to 800V battery voltage range, then the converter can operate with both 400V and 800V batteries, but high-efficiency operation cannot be achieved across the wide voltage range and it is difficult to cover the entire range when designing magnetic elements
Solution Approach 1:
The patent divides the voltage conversion function into two separate converters: a first converter optimized for 400V battery operation and a second converter optimized for 800V battery operation. Each converter is designed with magnetic elements and parameters optimized for its specific voltage range, allowing both converters to operate at high efficiency within their respective ranges. The segmentation resolves the contradiction by sacrificing universal coverage to achieve high efficiency in specific ranges.
2Adaptability or versatility
If a single converter is designed to cover the entire 400V to 800V battery voltage range, then the converter can operate with both 400V and 800V batteries, but the magnetic elements cannot be effectively designed to cover the entire range
Solution Approach 1:
The patent segments the voltage conversion task into two separate converters, each with magnetic elements designed for specific voltage ranges. The first converter's magnetic elements are optimized for 400V operation, while the second converter's magnetic elements are optimized for 800V operation. This segmentation makes magnetic element design feasible and effective, as each converter can use appropriately sized and optimized magnetic components for its voltage range.
Solution Approach 2:
The control unit provides universal control capability by managing both the first and second converters, allowing the system to adapt to different battery voltages. The control unit selects which converter to operate based on the battery voltage, providing universal adaptability across 400V and 800V ranges while each individual converter maintains specialized optimization for its specific range.
3Loss of energy
If separate converters are designed for 400V and 800V batteries, then high-efficiency operation can be achieved for each voltage range, but the device complexity increases
Solution Approach 1:
The control unit serves multiple functions by controlling both the first converter for 400V batteries and the second converter for 800V batteries. This universal control approach manages the complexity of having two converters through a single control interface, reducing the overall system complexity while maintaining the efficiency benefits of specialized converters for each voltage range.
Data Source
AI summary
A converter according to one embodiment of the present invention comprises: a first converter and a second converter for converting the input voltage into a first level voltage; a switching unit which connects the first converter and the second converter in series or in parallel; and an output unit to which the output terminal of the first converter and the output terminal of the second converter are connected in parallel.