Stacked matrix high frequency DC-AC power conversion system and method

• US 10,439,392 B2
• Filed: 02/20/2017
• Issued: 10/08/2019
• Est. Priority Date: 02/19/2016
• Status: Active Grant

• Current Assignee: Rhombus Energy Solutions, Inc. (BorgWarner Incorporated)
• Original Assignee: Rhombus Energy Solutions, Inc. (BorgWarner Incorporated)
• Inventors: Flett, Frederick
• Primary Examiner(s): Barnie, Rexford N
• Assistant Examiner(s): Inge, Joseph N
• Application Number:
  US15/437,340
• Publication Number:
  US 20170244248A1
• Time in Patent Office: 960 Days
• Field of Search: 307 52
• CPC Class Codes: H02J 3/00 Circuit arrangements for ac mains or ac distribution networks
• CPC Class Codes: H02M 1/0058 by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 7/4807 having a high frequency intermediate AC stage
• CPC Class Codes: H02M 7/4815 Resonant converters H02M7/4811 and H02M7/4826 take precedence
• CPC Class Codes: H02M 7/5387 in a bridge configuration
• CPC Class Codes: H02M 7/797 using semiconductor devices only
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A serial acquisition of multiple power sources via one or more multiplexers which is circulated in many corridors of a multi-port system with a resonant engine. A controller manages multiplexer/switches connecting a first plurality of DC power sources and an auxiliary DC power source to a circulator. A multiplexer/switch revolves each source of power to inverters for DC-AC conversion. Reciprocity of power sharing and management of signal routing between input power sources can be performed to maintain discrete operation between the input/output power sources and individual power inverters for precise load power delivery. Regenerative power from a motor load can be directed to “recharge” an input power source. The resonant engine applied to each power source provides a constant conduit of energy during off-operation/cycles.

Claims

1. A multi-port DC-AC power conversion system, comprising:

at least one or more primary DC power sources electrically connected to a controllable first input power switch;

an auxiliary DC power source electrically connected to a controllable second input power switch;

a power circulator electrically connected to the second input power switch and to the first input power switch, wherein the first power switch connection is either direct or indirectly via an controllable intermediary switch and a power recuperator, wherein the power recuperator is a resonant circuit;

a controllable output power switch electrically connected to the power circulator;

at least one or more inverter stages electrically connected to the output power switch,

wherein a power pathway is formed between the one or more primary DC power sources and the auxiliary DC power source and the one or more inverter stages; and

a controller, controlling an operation and switching frequency of;

the first input power switch to conduct power between a selected one or more primary DC power source to the power circulator,

the second input power switch to conduct power between the auxiliary DC power source to the power circulator, and

the output power switch to conduct power between the power circulator to a selected one or more inverter stage,

wherein DC power input from the power sources is converted to an isolated AC power from the selected one or more inverter stages.

2. The system of claim 1, wherein at least one of the first input power, second input power, controllable intermediary, and output power switches is a multiplexer switch.

3. The system of claim 2, wherein the controller controls the first input power multiplexer switch to repeatedly cycle though a plurality of the primary DC power sources.

4. The system of claim 2, wherein the controller controls the output power multiplexer switch to output power through a plurality of inverter stages.

5. The system of claim 1, wherein the system provides single phase AC power at an output of a single inverter stage and three phase AC power at the outputs of three inverter stages.

6. The system of claim 1, wherein at least one of the first input power, second input power, controllable intermediary, and output power switches is a bi-matrix switch.

7. The system of claim 1, wherein the controller controls the switches to only use power from a selected primary DC power source or the auxiliary DC power source.

8. The system of claim 1, wherein the controller controls the switches to alternatively use power from both a selected primary DC power source and the auxiliary DC power source.

9. The system of claim 1, wherein the controller controls the first and second input power switches to direct power from the auxiliary power source to one or more of the primary DC power sources, or direct power from one or more of the primary DC power sources to the auxiliary power source.

10. The system of claim 1, further comprising a load electrically connected to an inverter stage, wherein the controller controls the first and second input power switches and inverter(s) to direct power generated from the load to at least one of the primary DC power sources and the auxiliary power source.

11. The system of claim 1, wherein the controller controls the first input power switch and the intermediary switch to cause resonance in the recuperator stage, wherein energy is optionally fed to the power circulator or to at least one of the primary DC power sources.

12. The system of claim 1, further comprising a rectified AC grid as another input to the power circulator.

13. The system of claim 1, wherein at least one of the primary DC power sources and the auxiliary power source is a rechargeable battery.

14. The system of claim 1, wherein at least one of the primary DC power sources and the auxiliary power source is a solar panel.

15. A method for DC-AC conversion, comprising:

electrically connecting at least one or more primary DC power sources to a controllable first input power switch;

electrically connecting an auxiliary DC power source to a controllable second input power switch;

electrically connecting a power circulator to the second input power switch and to the first input power switch, wherein the first power switch connection is either direct or indirectly via an controllable intermediary switch and a power recuperator, wherein the power recuperator is a resonant circuit;

electrically connecting a controllable output power switch to the power circulator;

electrically connecting at least one or more inverter stages to the output power switch,

wherein a power pathway is formed between the one or more primary DC power sources and the auxiliary DC power source and the one or more inverter stages; and

controlling an operation and switching frequency of;

the first input power switch to conduct power between a selected one or more primary DC power source to the power circulator,

the second input power switch to conduct power between the auxiliary DC power source to the power circulator, and

the output power switch to conduct power between the power circulator to a selected one or more inverter stage,

wherein DC power input from the power sources is converted to an isolated AC power from the selected one or more inverter stages.

16. The method of claim 15, further comprising, switching the first input power switch to cycle though a plurality of the primary DC power sources.

17. The method of claim 15, further comprising, switching the output power multiplexer switch to output power through a plurality of inverter stages.

18. The method of claim 15, further comprising, switching the switches to only use power from a selected primary DC power source or the auxiliary DC power source.

19. The method of claim 15, further comprising, switching the switches to alternatively use power from both a selected primary DC power source and the auxiliary DC power source.

20. The method of claim 15, further comprising, switching the first and second input power switches to direct power from the auxiliary power source to one or more of the primary DC power sources, or direct power from one or more of the primary DC power sources to the auxiliary power source.

21. The method of claim 15, further comprising:

electrically connecting a load to an inverter stage; and

switching the first and second input power switches and inverter(s) to direct power generated from the load to at least one of the primary DC power sources and the auxiliary power source.

22. The method of claim 15, further comprising, switching the first input power switch and the intermediary switch to cause resonance in the recuperator stage, wherein energy is optionally fed to the power circulator or to at least one of the primary DC power sources.