Variable DC Link Voltage Boost Converter for Partial-Load Efficiency
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Solution Overview
Problem
Existing DC to DC converters in HVAC systems face inefficiencies when powering variable speed electric machines, particularly at partial loads, due to fixed output voltages that do not optimize energy usage and lead to increased power losses and reduced component lifespan.
Innovation Solution
The implementation of a multiple tapped winding electromagnetic coil DC to DC boost converter system that generates variable boosted voltages based on sensed load parameters, using a controller to manage switches and inductors to optimize inductance and reduce power losses, and incorporating a DC link capacitor for enhanced efficiency and extended component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a fixed output voltage DC to DC converter is used, then the converter structure is simple, but the electrical efficiency is reduced and power losses increase at partial loads
Solution Approach 1:
The patent implements a dynamic voltage selection mechanism where the converter switches between multiple discrete voltage levels (first boosted voltage and second boosted voltage) based on real-time load conditions. The controller monitors load parameters and dynamically selects the appropriate voltage level, transforming the static fixed-voltage converter into a dynamic adaptive system that optimizes efficiency across varying load conditions.
Solution Approach 2:
The patent changes the output voltage parameter from a fixed value to a variable parameter with at least two discrete levels. By adjusting the output voltage based on load conditions (full load versus partial load), the system optimizes electrical efficiency and reduces power losses without requiring a completely complex continuous regulation mechanism.
2Duration of action of stationary object
If a fixed output voltage is used, then the converter design is straightforward, but component lifespan is reduced due to non-optimized energy usage
Solution Approach 1:
The system dynamically adapts its operating voltage based on load conditions, preventing components from operating under suboptimal stress conditions. By switching between appropriate voltage levels rather than maintaining a fixed high voltage, the system reduces unnecessary electrical stress on components, thereby extending their operational lifespan.
Solution Approach 2:
The converter system monitors its own load conditions and automatically selects the appropriate voltage level without external intervention. This self-regulating mechanism ensures components operate under optimal conditions throughout their lifespan, extending their durability while maintaining straightforward converter design.
3Use of energy by moving object
If a single boosted voltage is generated, then the converter structure is simple, but energy utilization is not optimized at partial loads
Solution Approach 1:
The patent implements dynamic voltage selection where the controller monitors load parameters and switches between at least two boosted voltage levels based on whether the load is at full capacity or partial load. This dynamic adaptation maximizes energy utilization efficiency across different operating conditions.
Solution Approach 2:
The output voltage parameter is changed from a single fixed value to multiple discrete levels that can be selected based on load conditions. This parameter variation enables optimized energy utilization without requiring a completely complex continuous regulation system.
4Productivity
If variable boosted voltages are sourced based on load, then electrical efficiency is optimized, but the converter structure becomes more complex
Solution Approach 1:
The patent implements a dynamic voltage selection mechanism that switches between multiple discrete voltage levels based on real-time load monitoring. This dynamic approach optimizes electrical efficiency across varying operating conditions while maintaining a practical converter structure through discrete rather than continuous regulation.
Solution Approach 2:
The system varies the output voltage parameter between at least two boosted voltage levels based on load conditions, achieving optimized electrical efficiency without requiring overly complex converter architecture. The parameter change approach balances performance optimization with structural simplicity.
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
This solution optimizes electrical efficiency, extends component lifespan, and achieves maximum energy utilization from limited energy sources, meeting emissions standards and improving system performance, especially at partial loads where most runtime occurs.
Implementation Method 1
A typical switch-mode boost converter includes an inductor, a switch, and a flywheel diode. The first inductor and/or the second inductor can be a tapped winding electromagnetic coil with or without a magnetic core.
Implementation Method 2
incorporating a DC link capacitor for enhanced efficiency and extended component life
Data Source
AI summary
An inverter-converter system includes a DC source, a DC to DC boost converter, a DC link capacitor, an inverter circuit, a variable speed electric machine, and a controller. The DC to DC boost converter receives an input DC voltage from the DC source. The inverter circuit converts the variable boosted voltage to an AC voltage to drive the variable speed electric machine. The controller senses a plurality of parameters from the variable speed electric machine, and controls the DC to DC boost converter to boost up the input DC voltage to a variable output voltage based on the plurality of parameters and/or the voltage (or load) needed by the variable speed electric machine. The design of the inverter-converter system can achieve an electrical efficiency and cost savings for the overall system.