Variable-Phase Power Converter With Four-Conductor PFC Switching
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Solution Overview
Problem
Existing electric vehicle charging systems face inefficiencies in converting three-phase AC power to DC power, often requiring larger return wires and complex configurations, which can lead to component sizing issues and reduced efficiency.
Innovation Solution
A power converter with a bridgeless totem pole power factor correction circuit and a DC-to-DC converter, utilizing four conductors to handle both single-phase and three-phase electrical power, allowing for flexible operation modes and reduced component sizing through strategic switching of inductors and transistors based on voltage and current phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If larger return wires are implemented to accommodate ground currents in four-wire wye configurations, then the system can handle three-phase power, but the component sizing becomes more complex and efficiency reduces
Solution Approach 1:
The power converter is designed with a universal interface that can operate in both single-phase and three-phase modes using the same four conductors. The system dynamically reconfigures its internal circuitry based on the input power type, eliminating the need for different wire sizes or complex component configurations for different power phases.
Solution Approach 2:
The system dynamically switches between single-phase and three-phase operating modes based on the detected input power configuration. The controller adjusts the operation of the power factor correction circuit and DC-DC converter in real-time, optimizing component utilization and simplifying the overall system design.
2Power
If traditional power converter designs are used, then three-phase power conversion is achieved, but the system requires larger and more complex component configurations
Solution Approach 1:
The patent merges the handling of single-phase and three-phase power conversion into a single integrated power converter design. The same four conductors and core circuitry are used for both power types, reducing component configuration complexity while maintaining full three-phase power conversion capability.
3Productivity
If smaller conductors and transistors are used, then component sizing is reduced and efficiency improved, but the system may not accommodate higher current loads
Solution Approach 1:
The system dynamically adapts its current handling capability based on the operating mode. In three-phase mode, the distributed current across multiple conductors allows smaller individual conductor sizes while maintaining total current capacity. The controller optimizes the switching patterns to distribute loads efficiently, enabling smaller components to handle the required current loads reliably.
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 efficient conversion of AC power to DC power with reduced component sizing, improved safety, and increased efficiency by allowing smaller conductors and transistors, while maintaining flexibility in handling different power phases, thus addressing the inefficiencies in existing systems.
Implementation Method 1
The power factor correction circuit is configured to convert an input single-phase electrical power to a first DC electrical power
Implementation Method 2
The power factor correction circuit is further configured to convert an input three-phase electrical power to the first DC electrical power
Implementation Method 3
the power factor correction circuit includes four inductors connected in series with the four interface conductors respectively
Data Source
AI summary
A power converter incudes a power factor correction circuit and a controller. The power factor correction circuit is configured to convert an input single-phase electrical power to a first DC electrical power. An active phase of the input single-phase electrical power is received in parallel through two of four conductors. A return phase of the input single-phase electrical power is received in parallel through two others of the four conductors. The power factor correction circuit is also configured to convert an input three-phase electrical power to the first DC electrical power. Three active phases of the input three-phase electrical power are received through three of the four conductors. The return phase is received through a fourth of the four conductors. The controller is configured to control the power factor correction circuit to operate in the single-phase input mode and the three-phase input mode in response to a control signal.