Parallel Modular Converter Architecture

• US 20160094039A1
• Filed: 09/30/2014
• Published: 03/31/2016
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Solodovnik, Eugene V., Karimi, Kamiar J., Liu, Shengyi, Gao, Lijun, Krolak, Matthew J., Winstanley, Adam J.
• Granted Patent: US 10,079,493 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B64D 2221/00 Electric power distribution systems onboard aircraft
• CPC Class Codes: G05B 23/0286 Modifications to the monitored process, e.g. stopping operation or adapting control
• CPC Class Codes: H02J 2310/44 for aircrafts
• CPC Class Codes: H02J 4/00 Circuit arrangements for mains or distribution networks not specified as ac or dc
• CPC Class Codes: H02M 1/0048 Circuits or arrangements for reducing losses using snubbers H02M1/34
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/325 with means for allowing continuous operation despite a fault, i.e. fault tolerant converters
• CPC Class Codes: H02M 7/493 the static converters being arranged for operation in parallel
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 29/68 based on the temperature of a drive component or a semiconductor component
• 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 system and method for providing power to a vehicle is disclosed. The system can include a plurality of parallel module converter modules (“modules”) each capable of supplying a predetermined electrical load. The plurality of parallel module converter modules can be networked to form a parallel module converter (“converter”) for prioritizing and allocating each electrical load to one or more parallel module converter modules. Each module can include an internal protection controller and a logic controller. The individual modules can provide power to various loads in the vehicle either alone, or in concert with other modules. The system can enable fewer power controllers to be used, saving weight and time. The controllers in the system can also be utilized at a higher level reducing unnecessary redundancy.

Claims

1. A first parallel module converter module comprising:

a logic processor to determine a first pulse width modulation (PWM) frequency and duration and generate a corresponding first control signal;

a motor control digital signal processor (DSP) to generate a PWM signal based on the first control signal;

a gate driver to activate an inverter to produce an alternating current (AC) output signal based on the PWM signal; and

a module communications bus to communicate between the first parallel module converter module and a second parallel module converter module.

2. The module of claim 1, further comprising an AC electromagnetic interference (EMI) filter to remove noise from the AC output signal.

3. The module of claim 1 further comprising:

a protection processor to monitor one or more first parallel module converter module inputs and one or more first parallel module converter module outputs,

wherein the protection processor deactivates the first parallel module converter module when a fault is detected.

4. The module of claim 3, wherein the protection processor is in communication with the gate driver to deactivate the first parallel module converter module when a fault is detected.

5. The module of claim 3, the protection processor comprising one or more temperature sensors monitoring one or more of a gate driver temperature, an inverter temperature, and an AC output temperature,

wherein a fault is detected if one or more of the gate driver temperature, inverter temperature, and the AC output temperature is above a predetermined temperature.

6. The module of claim 3, the protection processor comprising one or more shoot-through sensors to detect shoot-through current on one or more of the first parallel module converter module outputs,

wherein a fault is detected if the shoot-through current on one or more of the first parallel module converter module outputs is above a predetermined current.

7. A parallel module converter comprising:

a first parallel module converter module to provide a first alternating current (AC) output signal and connected to a module communications bus;

a second parallel module converter module to provide a second AC output signal and connected to the module communications bus;

a master logic controller to assign a first load to one or more of the first parallel module converter module and the second parallel module converter module;

the module communications bus connecting the first parallel module converter module and the second parallel module converter module; and

a master communications controller connected to the module communications bus and the master logic controller to route messages therebetween.

8. The parallel module converter of claim 7, wherein the master logic controller assigns the first load to the first parallel module converter module and a second load to the second parallel module converter module.

9. The parallel module converter of claim 7, wherein the master logic controller places the first parallel module converter module and the second parallel module converter module in parallel using a power switching network and assigns the first load to the first parallel module converter module and the second parallel module converter module.

10. The parallel module converter of claim 7, further comprising:

a third parallel module converter module to provide a third AC output signal and connected to the module communications bus,

wherein the master logic controller places the first parallel module converter module, the second parallel module converter module, and the third parallel module converter module in parallel using a power switching network and assigns the first load to the first parallel module converter module, the second parallel module converter module, and the third parallel module converter module.

11. The parallel module converter of claim 7, further comprising:

a master protection controller to monitor one or more first parallel module converter module inputs and outputs, and one or more second parallel module converter module inputs and outputs,

wherein the protection controller deactivates the first parallel module converter module, the second parallel module converter module, or both the first parallel module converter module and second parallel module converter module when a fault is detected.

12. The parallel module converter of claim 11, the one or more first parallel module converter module inputs and the one or more second parallel module converter module inputs comprising one or more of an input voltage and an input current.

13. The parallel module converter of claim 11, the one or more first parallel module converter module outputs and the one or more second parallel module converter module outputs comprising one or more of an output voltage and an output current.

14. The parallel module converter of claim 7, further comprising:

a master data logger to log one or more datasets; and

a data storage medium to store the one or more datasets.

15. The parallel module converter of claim 14, wherein the one or more datasets comprise one or more of master logic controller commands, master communications controller messages, failure messages, and sensor readings.

16. The parallel module converter of claim 14, further comprising:

a data logging bus connecting the master data logger and the data storage medium,

wherein data logging communications are communicated via the data logging bus, and

wherein control communications are communicated via the parallel module converter module communications bus.

17. A method of providing power comprising:

connecting a first parallel module converter module and second parallel module converter module, and a master logic controller with a parallel module converter module communications bus;

routing communications between the first parallel module converter module, the second parallel module converter module, and the master logic controller with a master communications controller;

receiving one or more load requests from one or more aircraft systems at the master logic controller; and

assigning the one or more load requests to the first parallel module converter module, the second parallel module converter module, or both with the master logic controller,

wherein the first parallel module converter module provides a first alternating current (AC) signal and the second parallel module converter module provides a second AC signal.

18. The method of claim 17, further comprising:

receiving a first load request from a first aircraft system at the master logic controller;

placing the first parallel module converter module and the second parallel module converter module in parallel with a power switching network; and

assigning the first load request to the first parallel module converter module and the second parallel module converter module.

19. The method of claim 17, further comprising:

receiving a first load request at the master logic controller from a first aircraft system;

placing the first parallel module converter module, the second parallel module converter module, and a third parallel module converter module in parallel with a power switching network; and

assigning the first load request to the first parallel module converter module, the second parallel module converter module, and the third parallel module converter module,

wherein the third parallel module converter module provides a third AC output signal.

20. The method of claim 17, further comprising:

receiving a first load request from the one or more aircraft systems at the master logic controller;

placing the first parallel module converter module and the second parallel module converter module in parallel with a power switching network;

assigning the first load request to the first parallel module converter module and the second parallel module converter module with the master logic controller;

detecting a fault in the first parallel module converter module with a master protection parallel module converter module;

placing the second parallel module converter module and a third parallel module converter module in parallel with the power switching network;

assigning the first load request to the second parallel module converter module and the third parallel module converter module with the master logic controller; and

deactivating the first parallel module converter module with the master protection controller.

21. The method of claim 17, further comprising:

receiving a first load request and a second load request from the one or more aircraft systems at the master logic controller; and

assigning the first load request to the first parallel module converter module and the second load request to the second parallel module converter module with the master logic controller.

22. A method for providing power comprising:

receiving a request for a first load from an external aircraft system at a master logic controller;

assigning the first load to a first parallel module converter module with the master logic controller;

providing a first motor control algorithm to the first parallel module converter module with a control switching network; and

connecting the first parallel module converter module to the first load with a first switch of a power switching network.

23. The method of claim 22, further comprising:

placing the first parallel module converter module and a second parallel module converter module in parallel with the power switching network; and

assigning the first load to the first parallel module converter module and the second parallel module converter module with the master logic controller.

24. The method of claim 22, further comprising:

receiving a request for a second load from the external aircraft system at the master logic controller;

assigning the second load to a second parallel module converter module with the master logic controller;

providing a second motor control algorithm to the second parallel module converter module with the control switching network; and

connecting the second parallel module converter module to the second load with a second switch of the power switching network.

25. The method of claim 24, wherein the first motor control algorithm, the second motor control algorithm, or both the first and second motor control algorithms comprise a field oriented control (FOC) algorithm.

26. The method of claim 24, wherein the first control algorithm, the second control algorithm, or both the first and second motor control algorithms comprise direct torque control (DTC) algorithm.

27. The method of claim 24, wherein the first control algorithm, the second control algorithm, or both the first and second motor control algorithms comprise a voltage over frequency (V/F) algorithm.

28. A method for providing power comprising:

receiving a request for a first load from a first external aircraft system at a master logic controller;

receiving a request for a second load from a second external aircraft system at the master logic controller;

placing a first parallel module converter module and a second parallel module converter module in parallel with a power switching network;

assigning the first load to a the first parallel module converter module and the second parallel module converter module with the master logic controller;

assigning the second load to a third parallel module converter module with the master logic controller;

detecting an increase in the second load and a decrease in the first load with the master logic controller;

placing the second parallel module converter module and the third parallel module converter module in parallel with the power switching network; and

reassigning the second parallel module converter module to the second load with the master logic controller.

29. The method of claim 28, further comprising:

receiving a request to disconnect the first load at the master logic controller; and

disconnecting the first parallel module converter module from the first load with the power switching network.

30. The method of claim 28, further comprising:

receiving a request to disconnect the second load at the master logic controller; and

disconnecting the second parallel module converter module and the third parallel module converter module from the second load with the power switching network.

31. The method of claim 28, wherein the request for the first load and the second load comprise a first load type and a second load type,

wherein assigning the first load further comprises assigning a first control algorithm with a control switching network, and

wherein assigning the second load further comprises assigning a second control algorithm with the control switching network.

32. A system comprising:

a master logic controller to receive a first load request and a second load request from a vehicle controller;

a control switching network, comprising a plurality of control algorithms, in communication with the master logic controller;

a plurality of inverters in communication with the control switching network for converting one or more direct current (DC) input signals to one or more alternating current (AC) output signals; and

a power switching network, comprising a plurality of switches to connect the plurality of inverters to one or more electrical loads,

wherein the controller activates a first group of the one or more switches in the power switching network to connect a first group of the one or more inverters to a first load in response to the first load request, and

wherein the controller activates a second group of the one or more switches in the power switching network to connect a second group of the one or more inverters a second load in response to the second load request.

33. The system of claim 32, wherein the control switching network assigns a first control algorithm to the first group of the one or more inverters and a second control algorithm to the second group of the one or more inverters.

34. A method of providing power comprising:

receiving a request at a master logic controller to power a first load from a first external aircraft system;

determining the power to be provided to the first load with the master logic controller;

determining a first plurality of parallel module converter module to be activated to power the first load with the master logic controller;

determining a plurality of parameters of a first control algorithm for the first plurality of parallel module converter modules with a control switching network;

instructing a power switching network to connect the first plurality of parallel module converter modules in parallel with the first load; and

activating the first control algorithm to provide the first load to the external aircraft system.

35. The method of claim 34, further comprising:

monitoring the temperatures of the first plurality of parallel module converter modules with one or more temperature sensors; and

removing the first control algorithm from a first parallel module converter module of the first plurality of parallel module converter modules and applying it to a second parallel module converter module if the temperature of a first parallel module converter module exceeds a predetermined value.

36. The method of claim 34, further comprising:

receiving a request at the master logic controller to power a second load from a second external aircraft system;

determining the power to be provided to the second load with the master logic controller;

determining a second plurality of parallel module converter module to be activated to power the second load with the master logic controller;

determining a plurality of parameters of a second control algorithm with the control switching network;

instructing the power switching network to connect the second plurality of parallel module converter modules in parallel with the second load; and

activating the second control algorithm to provide the second load to the second external aircraft system.