Single-Stage Three-Phase Power Conversion Merging Rectification and DC/DC
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Solution Overview
Problem
Existing three-phase switch power supply circuits suffer from reduced conversion efficiency, high cost, limited service life, and complex control algorithms due to their two-stage high-frequency structure, excessive components, and non-return-zero power modes, which restrict the selection of high-efficiency topological circuits.
Innovation Solution
A single-stage three-phase power supply conversion device incorporating a three-phase rectification and commutation module and a DC/DC conversion module, reducing the number of control variables and simplifying control strategies, while promoting power factor correction and efficient AC/DC or DC/AC conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a two-stage high-frequency switch structure is used, then power factor correction can be achieved, but conversion efficiency is reduced
Solution Approach 1:
The patent merges the power factor correction function and DC/DC conversion function into a single integrated circuit stage. The three-phase rectification and commutation module is directly connected to the DC/DC conversion module, eliminating the need for separate energy storage capacitors and intermediate circuits. This integration reduces component count, decreases conduction losses, and improves overall conversion efficiency while maintaining power factor correction capability.
2Loss of energy
If three high-frequency inductors are used, then power factor correction is achieved, but total cost increases significantly
Solution Approach 1:
The patent eliminates the need for three separate high-frequency inductors by integrating the power factor correction function into the DC/DC conversion module. The rectification and commutation module shares magnetic components with the DC/DC conversion module, reducing the total number of inductors from three to one or two, thereby significantly reducing material costs and manufacturing complexity.
3Loss of energy
If eighteen high-frequency diodes and three high-frequency switch triodes are used, then power factor correction is achieved, but total cost increases
Solution Approach 1:
The patent integrates the rectification and commutation functions into a unified module that shares switching devices with the DC/DC conversion module. Instead of using eighteen diodes and three triodes separately, the design uses a combined module with fewer switching elements that perform both power factor correction and voltage conversion functions, reducing component count and cost.
4Loss of energy
If two high-voltage energy-storage capacitors are used, then power factor correction is achieved, but service life is hindered
Solution Approach 1:
The patent eliminates the need for separate high-voltage energy storage capacitors by integrating the energy storage function into the DC/DC conversion module. The commutation module and DC/DC module share the same energy storage inductors, removing the stress of high-voltage capacitor operation and extending the overall system service life.
5Loss of energy
If a Vienna structure preliminary stage is used, then power factor correction is achieved, but output voltage becomes excessively high causing processing stress
Solution Approach 1:
The patent combines the power factor correction stage and DC/DC conversion stage into a single integrated module. The rectification and commutation module directly feeds the DC/DC conversion module, allowing the output voltage to be regulated at the appropriate level for subsequent processing stages, eliminating the excessive voltage output problem of the Vienna structure.
6Loss of energy
If high-voltage energy-storage capacitance is used, then power factor correction is achieved, but electrified initial impact current becomes extremely large
Solution Approach 1:
The patent integrates the power factor correction and DC/DC conversion functions, eliminating separate high-voltage energy storage capacitors. The shared energy storage inductors in the integrated module provide soft-start capability and current limiting, preventing extremely large initial impact currents while maintaining power factor correction performance.
7Loss of energy
If a three-phase high-frequency switch is used, then power factor correction is achieved, but control loop algorithm complexity increases
Solution Approach 1:
The patent integrates power factor correction and DC/DC conversion into a single control loop. The unified module allows for simplified control strategy where the switching devices are controlled based on a single set of reference signals, reducing the complexity of multi-loop control algorithms while maintaining effective power factor correction.
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 enhances conversion efficiency, reduces costs, extends service life, and simplifies control complexity, achieving optimal power factor correction and flexible topological circuit selection.
Implementation Method 1
a three-phase rectification and commutation module having a three-phase AC connection end, a DC source first connection end, a DC source second connection end and a DC source third connection end
Implementation Method 2
a DC/DC conversion module having a first connection end, a second connection end, a third connection end, a DC source positive connection end and a DC source negative connection end
Data Source
AI summary
A single-stage three-phase power supply conversion device includes a three-phase rectification and commutation module and a DC/DC conversion module; the three-phase rectification and commutation module has a three-phase AC connection end, a DC source first connection end, a DC source second connection end and a DC source third connection end, and the DC/DC conversion module has a first connection end, a second connection end, a third connection end, a DC source positive connection end and a DC source negative connection end; a three-phase AC source is connected to the three-phase AC connection end of the three-phase rectification and commutation module, the DC source first connection end of the three-phase rectification and commutation module is connected to the first connection end of the DC/DC conversion module, the DC source second connection end is connected to the second connection end of the DC/DC conversion module.