Three-Level Inverter Power Converter for Compact Voltage Step-Up

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Solution Overview

Problem

Existing power converters used in systems with high-capacity storage batteries, such as electrical vehicles, face challenges in reducing size while meeting the requirements for high voltage applications.

Innovation Solution

The proposed electrical power converter incorporates a three-level inverter connected to a rotating electrical machine with multi-phase windings, a connector, and a controller. This configuration allows for a voltage step-up task to be performed without additional circuits, reducing the size of the power converter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If additional structures are added to meet high voltage requirements, then the power converter can handle high voltage, but the size of the power converter increases

Engineering Contradiction:
Improvevoltage handling capabilityVSAvoidpower converter size
Core Design Contradiction:
PowerVSVolume of moving object

Solution Approach 1:

The three-level inverter structure enables the power converter to handle both high voltage and low voltage operations using the same circuit configuration. The inverter can operate in different modes (high voltage charging and low voltage charging) without requiring additional dedicated circuits, thus achieving multi-functionality with a single structure.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The controller dynamically switches between high voltage charging mode and low voltage charging mode based on the charging requirements. The three-level inverter can dynamically adjust its operation to handle different voltage levels, enabling adaptive voltage management without physical structural changes.

Inventive Principle:
Principle #15Dynamics

2Object-generated harmful factors

If a three-level inverter is used to reduce leakage current, then leakage current is reduced, but the device complexity increases

Engineering Contradiction:
Improveleakage currentVSAvoidinverter structure complexity
Core Design Contradiction:
Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The three-level inverter divides the voltage handling into three levels (positive DC bus, neutral point, and negative DC bus) using two series-connected capacitors. This segmentation allows the inverter to reduce leakage current by providing multiple discharge paths while maintaining a structured and manageable circuit configuration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The neutral point in the three-level inverter acts as an intermediary that provides an additional reference potential and discharge path. This intermediary structure enables leakage current reduction by offering alternative current paths without significantly increasing overall system complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 enables the power converter to be compact while effectively managing high voltage requirements, enhancing system efficiency and reducing production costs.

Implementation Method 1

The switches work to connect the windings with a positive side of the first electrical storage device, a neutral point between a negative side of the first electrical storage device and a positive side of the second electrical storage device, or a negative side of the second electrical storage device

Methodology Applied
Scientific EffectElectrical switching:

Implementation Method 2

The controller works to start a voltage step-up task to perform the switching operations with the charger connected to the three-level inverter through the neutral point connector and the negative connector to create flows of electrical current through the three-level inverter and the windings, thereby stepping-up charging voltage

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250141367A1Electrical power converter
Publication Date: 2025.05.01 DENSO CORP
  • US20250141367A1 patent drawing
  • US20250141367A1 patent drawing
  • US20250141367A1 patent drawing

AI summary

An electrical power converter includes a three-level inverter and a rotating electrical machine which includes windings. The three-level inverter includes first and second electrical storage devices, and switches. A positive side of the first electrical storage device is connected to a positive terminal of the storage battery. A negative side of the second electrical storage device is connected to a negative terminal of the storage battery. The electrical power converter also includes a connector and a controller. The connector achieves electrical connection of the electrical device with the three-level inverter and also achieves electrical connection of the electrical device with the storage battery through the neutral point. The controller works to control switching operations of the switches to achieve transmission of electrical power between the electrical device and the storage battery with the three-level inverter and the electrical device connected together through the connector.