Transport climate control system with a self-configuring matrix power converter
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Solution Overview
Problem
Transport climate control systems face inefficiencies due to the need for multiple power converters to accommodate different DC input voltages, leading to increased costs, complexity, and reliability issues when managing energy conversion in vehicles and transport containers.
Innovation Solution
A self-configuring matrix power converter that can adapt to different voltage levels, minimizing unused circuitry and magnetic components, allowing it to operate efficiently with both 24 VDC and 48 VDC systems by reconfiguring transformer windings and switches, thus optimizing energy conversion and reducing the need for multiple converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power converters are designed for different DC input voltages (24VDC and 48VDC), then each converter can be optimized for its specific voltage, but the system complexity increases and multiple components must be stocked and maintained
Solution Approach 1:
The patent implements a universal power converter design that can operate with multiple DC input voltages (24VDC, 48VDC, and other voltages) through a single unified hardware platform. The converter uses a matrix switch network that can be configured through software to accommodate different voltage levels, eliminating the need for separate hardware designs for each voltage standard. This multi-functional approach maintains reliability across different voltage systems while reducing device complexity by consolidating multiple converter types into one.
Solution Approach 2:
The patent employs dynamic reconfiguration of the power converter's internal circuitry through a matrix switch network controlled by a microcontroller. The converter can dynamically adjust its topology and switching patterns based on the detected input voltage level, transitioning between different operational modes to optimize performance for 24VDC, 48VDC, or other voltages. This dynamic adaptability allows a single converter to replace multiple static designs.
2Adaptability or versatility
If multiple power converters are used to support different voltage levels, then voltage-specific optimization is achieved, but manufacturing costs increase and production becomes more complex
Solution Approach 1:
The patent creates a universal power converter platform that manufactures a single type of hardware capable of supporting multiple voltage standards (24VDC, 48VDC, and others). This eliminates the need for separate production lines for different converter types, simplifying manufacturing processes, reducing inventory complexity, and lowering production costs while maintaining full voltage compatibility through software-controlled configuration.
Solution Approach 2:
The patent changes the operational parameters of the power converter through software configuration rather than hardware modification. The matrix switch network and control algorithms can be reprogrammed to accommodate different voltage levels, allowing the same manufactured unit to adapt to various voltage requirements. This parameter-based adaptability simplifies manufacturing by producing a standardized platform that can be flexibly configured for different applications.
3Reliability
If separate converters are designed for different voltage systems, then each converter can be optimized for its voltage, but service and maintenance become more difficult with multiple part types
Solution Approach 1:
The patent implements a universal service platform where a single converter design serves multiple voltage systems. This eliminates the need for technicians to stock and diagnose multiple different converter types, as one unified design handles 24VDC, 48VDC, and other voltages. Service parts, diagnostic tools, and training can be standardized across all installations, significantly improving ease of repair and maintenance while maintaining optimized performance for each voltage level through software configuration.
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 seamless operation across various voltage levels, reduces costs by reusing existing components, improves reliability, and simplifies maintenance by eliminating the need for multiple converter designs, thereby enhancing customer satisfaction and reducing errors.
Implementation Method 1
the inverter circuit is configured to convert a first AC voltage from an energy source to a first DC voltage
Implementation Method 2
the controller is configured to control the self-configuring matrix power converter to convert the first DC voltage to a first output DC voltage to charge the first DC energy storage, and/or to a second output DC voltage to charge the second DC energy storage
Implementation Method 3
the controller is configured to control the self-configuring matrix power converter to convert a first input DC voltage from the first DC energy storage and/or a second input DC voltage from the second DC energy storage to a second DC voltage. The inverter circuit is configured to convert the second DC voltage to an AC voltage to drive the compressor
Data Source
AI summary
A transport climate control system is disclosed. The transport climate control system includes a self-configuring matrix power converter having a charging mode, an inverter circuit, a controller, a first DC energy storage and a second DC energy storage, and a compressor. The first DC energy storage and the second DC energy storage have different voltage levels. During the charging mode, the inverter circuit is configured to convert a first AC voltage from an energy source to a first DC voltage, the controller is configured to control the self-configuring matrix power converter to convert the first DC voltage to a first output DC voltage to charge the first DC energy storage, and/or to a second output DC voltage to charge the second DC energy storage.