DC power signal generation for electro-chemical reactor

• US 9,397,514 B2
• Filed: 03/13/2014
• Issued: 07/19/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: United Rentals Incorporated
• Original Assignee: BakerCorp. (BakerCorp International, Inc.)
• Inventors: Herber, Douglas J., Sullivan, Mark
• Primary Examiner(s): Siek, Vuthe
• Application Number:
  US14/209,489
• Publication Number:
  US 20140266074A1
• Time in Patent Office: 859 Days
• Field of Search: 320/166
• US Class Current: 1/1
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 3/285 Single converters with a plurality of output stages connected in parallel parallel operation of a plurality of converters in dc distribution networks H02J1/10

Abstract

Various systems, processes, and techniques may be used for converting alternating current power to direct current power for an electro-chemical reactor. In certain implementations, a system and a process may include the ability to receive an alternating current power signal, convert the alternating current signal to a direct current signal, and distribute the direct current signal to at least two power conversion modules coupled to a mounting structure. Each power conversion module may be able to convert a portion of the direct current signal to a high-frequency alternating current signal, adjust the voltage of the high-frequency alternating current signal, convert the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filter the direct current power signal. The system and the process may include the ability to combine the direct current power signals from the modules into an output direct current power signal for an electro-chemical reactor.

Claims

1. A system for converting alternating current power to direct current power for an electro-chemical reactor, the system comprising:

an input electrical connector adapted to receive an alternating current power signal;

a convertor adapted to convert the alternating current power signal to a direct current signal;

at least one power conversion module, each power conversion module comprising;

a convertor for converting a portion of the direct current signal to a high-frequency alternating current signal;

a transformer adapted to adjust the voltage of the high-frequency alternating current signal;

a convertor adapted to convert the voltage-adjusted high-frequency alternating current signal to a direct current power signal; and

a filter adapted to filter the direct current power signal;

a mounting structure adapted to receive a plurality of the power conversion modules;

a first bus adapted to distribute the direct current signal from the alternating current to direct current convertor to the power conversion modules;

a second bus adapted to receive the direct current power signals from the power conversion modules and combine the signals into an output direct current power signal;

an output electrical connector for conveying the output direct current power signal to an electro-chemical reactor; and

a polarity reverser adapted to reverse the polarity of the output direct current power signal,

wherein the polarity reverser reverses the polarity of the output direct current power signal at a prescribed time and for a prescribed duration.

2. The system of claim 1, wherein the mounting structure comprises a housing adapted to receive a plurality of power conversion modules.

3. The system of claim 2, wherein the mounting structure further comprises a shelf adapted to receive a plurality of power conversion modules, and the housing is adapted to receive the shelf.

4. The system of claim 3, wherein the shelf comprises a pair of bus bars, the bus bars comprising threaded apertures to which one or more power conversion modules may be bolted.

5. The system of claim 3, wherein the housing is adapted to receive a number of shelves, each shelf adapted to receive a number of power conversion modules.

6. The system of claim 5, further comprising an electrical output connector for each shelf.

7. A system for converting alternating current power to direct current power for an electro-chemical reactor, the system comprising:

an input electrical connector adapted to receive an alternating current power signal;

a convertor adapted to convert the alternating current power signal to a direct current signal;

at least one power conversion module, each power conversion module comprising;

a convertor for converting a portion of the direct current signal to a high-frequency alternating current signal;

a transformer adapted to adjust the voltage of the high-frequency alternating current signal;

a convertor adapted to convert the voltage-adjusted high-frequency alternating current signal to a direct current power signal; and

a filter adapted to filter the direct current power signal;

a mounting structure adapted to receive a plurality of the power conversion modules;

a first bus adapted to distribute the direct current signal from the alternating current to direct current convertor to the power conversion modules;

a second bus adapted to receive the direct current power signals from the power conversion modules and combine the signals into an output direct current power signal; and

an output electrical connector for conveying the output direct current power signal to an electro-chemical reactor, wherein each power conversion module comprises a controller, each controller adapted to determine the amount of power to be generated by the associated power conversion module and to control the direct current to alternating current convertor to generate the high-frequency alternating current signal.

8. The system of claim 7, wherein each controller is further adapted to monitor the direct current power signal being generated by the associated power conversion module and to adjust the alternating current signal based on the generated signal.

9. The system of claim 8, wherein each controller is further adapted to limit the direct current power signal being produced by the associated power conversion module and to generate a user alert if the limit is reached.

10. A system for converting alternating current power to direct current power for an electro-chemical reactor, the system comprising:

an input electrical connector adapted to receive an alternating current power signal;

a convertor adapted to convert the alternating current power signal to a direct current signal;

at least one power conversion module, each power conversion module comprising;

a convertor for converting a portion of the direct current signal to a high-frequency alternating current signal;

a transformer adapted to adjust the voltage of the high-frequency alternating current signal;

a convertor adapted to convert the voltage-adjusted high-frequency alternating current signal to a direct current power signal; and

a filter adapted to filter the direct current power signal;

a mounting structure adapted to receive a plurality of the power conversion modules;

a first bus adapted to distribute the direct current signal from the alternating current to direct current convertor to the power conversion modules;

a second bus adapted to receive the direct current power signals from the power conversion modules and combine the signals into an output direct current power signal;

an output electrical connector for conveying the output direct current power signal to an electro-chemical reactor; and

a master controller communicatively coupled to the available power conversion modules and adapted to;

determine the total output power signal for the system; and

assign portions of the total output power signal to the available power conversion modules.

11. The system of claim 10, wherein the master controller is further adapted to determine the number of power conversion modules that are available.

12. The system of claim 11, wherein the master controller is further adapted to discover and assign addresses to the power conversion modules.

13. The system of claim 11, wherein the master controller is further adapted to divide the available power conversion modules into at least two groups and assign a first output power to the first group and a second output power to the second group.

14. A method performed in a power convertor for converting alternating current power to direct current power for an electro-chemical reactor, the method comprising:

receiving an alternating current power signal;

converting the alternating current power signal to a direct current signal;

distributing the direct current signal to at least two power conversion modules coupled to a mounting structure, each power conversion module converting a portion of the direct current signal to a high-frequency alternating current signal, adjusting the voltage of the high-frequency alternating current signal, converting the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filtering the direct current power signal;

combining the direct current power signals from the power conversion modules into an output direct current power signal for an electro-chemical reactor;

determining, using one or more processors, the amount of power to be generated by the associated power conversion module; and

controlling the conversion of direct current signal to the high-frequency alternating current signal.

15. A method performed in a power convertor for converting alternating current power to direct current power for an electro-chemical reactor, the method comprising:

receiving an alternating current power signal;

converting the alternating current power signal to a direct current signal;

distributing the direct current signal to at least two power conversion modules coupled to a mounting structure, each power conversion module converting a portion of the direct current signal to a high-frequency alternating current signal, adjusting the voltage of the high-frequency alternating current signal, converting the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filtering the direct current power signal;

combining the direct current power signals from the power conversion modules into an output direct current power signal for an electro-chemical reactor;

monitoring, using one or more processors, the direct current power signal being generated by the associated power conversion module; and

adjusting the high-frequency alternating current signal based on the generated signal.

16. A method performed in a power convertor for converting alternating current power to direct current power for an electro-chemical reactor, the method comprising:

receiving an alternating current power signal;

converting the alternating current power signal to a direct current signal;

distributing the direct current signal to at least two power conversion modules coupled to a mounting structure, each power conversion module converting a portion of the direct current signal to a high-frequency alternating current signal, adjusting the voltage of the high-frequency alternating current signal, converting the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filtering the direct current power signal;

combining the direct current power signals from the power conversion modules into an output direct current power signal for an electro-chemical reactor;

limiting, using one or more processors, the direct current power signal being produced by the associated power conversion module; and

generating a user alert if the limit is reached.

17. A method performed in a power convertor for converting alternating current power to direct current power for an electro-chemical reactor, the method comprising:

receiving an alternating current power signal;

converting the alternating current power signal to a direct current signal;

distributing the direct current signal to at least two power conversion modules coupled to a mounting structure, each power conversion module converting a portion of the direct current signal to a high-frequency alternating current signal, adjusting the voltage of the high-frequency alternating current signal, converting the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filtering the direct current power signal;

combining the direct current power signals from the power conversion modules into an output direct current power signal for an electro-chemical reactor;

determining, using one or more processors, the total output power signal; and

assigning portions of the total output power signal to the available power conversion modules.

18. The method of claim 17, further comprising determining the number of power conversion modules that are available.

19. A method performed in a power convertor for converting alternating current power to direct current power for an electro-chemical reactor, the method comprising:

receiving an alternating current power signal;

converting the alternating current power signal to a direct current signal;

distributing the direct current signal to at least two power conversion modules coupled to a mounting structure, each power conversion module converting a portion of the direct current signal to a high-frequency alternating current signal, adjusting the voltage of the high-frequency alternating current signal, converting the voltage-adjusted high-frequency alternating current signal to a direct current power signal, and filtering the direct current power signal;

combining the direct current power signals from the power conversion modules into an output direct current power signal for an electro-chemical reactor;

determining, using one or more processors, a number of power conversion modules available for a first channel and available for a second channel; and

assigning portions of a first output power signal to the modules available for the first channel and portions of a second output power signal to the modules available for the second channel.