Three-Level Converter Switching for Grid and Off-Grid Efficiency

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Solution Overview

Problem

Existing photovoltaic inverters face inefficiencies and increased heat generation in both grid-connected and off-grid states, with some systems performing better in one mode but not the other, making it challenging to ensure efficient operation in both scenarios.

Innovation Solution

A three-level converter design that includes specific configurations of power switches and freewheeling branches, along with a control method that manages the switching of these components to optimize performance in both grid-connected and off-grid modes, improving efficiency and reducing system losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing photovoltaic inverter designs are used, then the inverter performs well in either grid-connected or off-grid state, but the efficiency deteriorates in the other state

Engineering Contradiction:
Improveinverter efficiencyVSAvoidperformance consistency across grid-connected and off-grid states
Core Design Contradiction:
ProductivityVSAdaptability or versatility

Solution Approach 1:

The inverter is divided into two independent full-bridge inverters (first full-bridge inverter and second full-bridge inverter) that can operate independently. Each full-bridge inverter has its own set of power switches and can function as a complete inverter unit, allowing the system to efficiently handle both grid-connected and off-grid modes by activating appropriate segments based on operating conditions.

Inventive Principle:
Principle #1Segmentation

2Device complexity

If a single-phase inverter design is used, then the structure is simple, but the efficiency and performance are insufficient in both grid-connected and off-grid states

Engineering Contradiction:
Improveinverter structureVSAvoidsystem efficiency
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

Two full-bridge inverter units are merged into a single three-level inverter system that shares common DC input ends and control architecture. This merging approach achieves high efficiency comparable to dual independent inverters while reducing overall device complexity through shared components and unified control.

Inventive Principle:
Principle #5Merging (Combining)

3Ease of manufacture

If existing inverter configurations are used, then cost is reduced in one operating mode, but system losses and heat generation increase

Engineering Contradiction:
Improvesystem costVSAvoidsystem losses and heat generation
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The inverter employs dynamic switching control where power switches are turned on and off based on real-time operating conditions (grid-connected or off-grid mode). This dynamic operation optimizes energy conversion efficiency, reduces unnecessary power losses, and minimizes heat generation by activating only the necessary circuit paths for each operating state.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS12057785B1Three-level converter and control method thereof
Publication Date: 2024.08.06 FOXESS CO LTD
  • US12057785B1 patent drawing
  • US12057785B1 patent drawing
  • US12057785B1 patent drawing

AI summary

A three-level converter includes a first power switch, which has a first end connected to a first DC input end and a first end of a third power switch. A second end of a second power switch is connected to a second DC input end and a second end of a fourth power switch. A connection point between a second end of the first power switch and a first end of the second power switch is a first AC output end. A connection point between a second end of the third power switch and a first end of the fourth power switch is a second AC output end. Fifth and sixth power switches are connected in series between the first AC output end and a neutral end. A seventh power switch is connected between the second AC output end and a connection point between the fifth and sixth power switches.