US-12620886-B2 - Multiport transformer enabled modular multiport power conversion system

US12620886B2US 12620886 B2US12620886 B2US 12620886B2US-12620886-B2

Abstract

A modular, multiport power conversion system includes a central transformer with a plurality of windings inductively connected to the central transformer. The plurality of windings are connected to ports able to connect to both AC and DC-devices, including both power sources and power consuming nodes. Each port is able to be selectively galvanically isolated, such that a controller is able to determine from which ports power is drawn and/or to which ports power is transferred. The system is operable to use zero voltage switching (ZVS) and/or zero current switching (ZCS) for each port to reduce power loss and increase efficiency, especially for high frequency embodiments.

Inventors

Haroon Inam

Assignees

DG Matrix, Inc.

Dates

Publication Date: 20260505
Application Date: 20250804

Claims (20)

1 . A modular multiport power system, comprising: a central transformer; a plurality of galvanically isolated ports coupled via inductive, capacitive, resistive, or hybrid coupling methods to the central transformer via windings; one or more voltage sensors and/or one or more current sensors for each of the plurality of galvanically isolated ports configured to detect voltage and/or current characteristics of each of the plurality of galvanically isolated ports; and at least one controller operable to selectively isolate one or more of the plurality of galvanically isolated ports; wherein at least one first port of the plurality of galvanically isolated ports is connected to one or more sources; wherein at least one second port of the plurality of galvanically isolated ports is connected to one or more loads; wherein the at least one controller is configured to selectively charge and/or discharge the one or more sources and the one or more loads; wherein the at least one controller is operable to detect a fault of one or more of the plurality of galvanically isolated ports based on the voltage and/or current characteristics using a fault detection algorithm, wherein the fault comprises an undercurrent condition, an overcurrent condition, an undervoltage condition, an overvoltage condition, and/or arcing; wherein each of the plurality of galvanically isolated ports includes a plurality of metal-oxide semiconductor field effect transistors (MOSFETs), integrated gate bipolar transistors (IGBTs), gallium nitride (GaN) or silicon carbide (SiC) devices, and/or any other suitable semiconductor devices in an AC switch or H-bridge configuration; and wherein the plurality of galvanically isolated ports includes AC and/or DC ports.
2 . The system of claim 1 , wherein each of the plurality of galvanically isolated ports includes a decoupling impedance module spanning connection points between the plurality of galvanically isolated ports and the central transformer, wherein the decoupling impedance module includes an inductor, a capacitor, a resistor, or combinations thereof.
3 . The system of claim 1 , wherein the plurality of galvanically isolated ports includes a combination of AC and DC ports.
4 . The system of claim 1 , wherein the one or more sources and/or the one or more loads includes at least one medium voltage source and/or medium voltage load.
5 . The system of claim 1 , wherein the one or more current sensors include open-loop, closed-loop, or flux gate current sensors.
6 . The system of claim 1 , wherein the at least one controller utilizes zero-voltage switching (ZVS) or zero current switching (ZCS) to manipulate current and/or voltage drawn by or supplied from the plurality of galvanically isolated ports.
7 . The system of claim 1 , wherein the at least one controller receives instructions to control a percentage of power drawn by or supplied from one of the plurality of galvanically isolated ports, and wherein the at least one controller is operable to adjust a duty cycle and/or phase for at least one of the plurality of galvanically isolated ports to achieve meet the percentage of power drawn by or supplied from the one of the plurality of galvanically isolated ports.
8 . The system of claim 1 , wherein the at least one controller includes at least one artificial intelligence module configured to determine which of the plurality of galvanically isolated ports to disconnect, ramp up, or ramp down based on the voltage and/or current characteristics detected by the one or more voltage sensors and/or one or more current sensors.
9 . The system of claim 1 , wherein the plurality of galvanically isolated ports includes four or more ports.
10 . The system of claim 1 , wherein the one or more sources and the one or more loads include solar PV, wind turbines, fuel cells, hydrogen systems, flywheels, capacitors, diesel gensets, natural gas generators, and/or any other energy storage devices.
11 . The system of claim 1 , wherein the at least one controller includes one or more cybersecurity modules configured to detect, mitigate, or respond to cyber threats, unauthorized access, and/or faults, thereby providing resilience and operational continuity for the system.
12 . The system of claim 1 , wherein the at least one controller includes software algorithms for adaptive real-time optimization, predictive analytics, fault prediction, self-diagnostics, prognostics, and/or autonomous maintenance.
13 . The system of claim 1 , wherein the at least one controller is operable to communicate via interfaces compliant with the Institute of Electrical and Electronics Engineers (IEEE), International Electrotechnical Commission (IEC), American National Standards Institute (ANSI) and/or any other standard for grid interoperability and integration.
14 . A modular multiport power system, comprising: a central transformer; a plurality of galvanically isolated ports coupled via inductive, capacitive, resistive, or hybrid coupling methods to the central transformer via windings; one or more voltage sensors and/or one or more current sensors for each of the plurality of galvanically isolated ports configured to detect voltage and/or current characteristics of each of the plurality of galvanically isolated ports; and at least one controller operable to selectively manipulate one or more of the plurality of galvanically isolated ports; wherein each of the plurality of galvanically isolated ports are connected to one or more sources and/or loads; wherein the at least one controller is operable to detect a fault of one or more of the plurality of galvanically isolated ports based on the voltage and/or current characteristics using a fault detection algorithm, wherein the fault comprises an undercurrent condition, an overcurrent condition, an undervoltage condition, an overvoltage condition, and/or arcing; wherein the at least one controller receives instructions to control a percentage of power drawn by or supplied from one of the plurality of galvanically isolated ports; and wherein the at least one controller is operable to adjust respective on-off duty cycles and phasing of the on-off duty cycles with respect to other ports, to achieve the percentage of power drawn by or supplied from the one of the plurality of galvanically isolated ports.
15 . The system of claim 14 , wherein each of the plurality of galvanically isolated ports includes a decoupling impedance module, wherein the decoupling impedance module includes an inductor, a capacitor, a resistor, or combinations thereof.
16 . The system of claim 14 , wherein the plurality of galvanically isolated ports includes a combination of AC and DC ports.
17 . The system of claim 14 , wherein the one or more sources and/or loads includes at least one medium voltage source and/or medium voltage load.
18 . The system of claim 14 , wherein the one or more current sensors include open-loop, closed-loop, or flux gate current sensors.
19 . The system of claim 14 , wherein the system includes a user interface, and wherein user interface is configured to receive data from the one or more voltage sensors and/or the one or more current sensors and to indicate which ports have faults.
20 . The system of claim 14 , wherein the one or more sources and/or loads include at least one battery, at least one solar cell, at least one wind turbine, at least one power plant, at least one microgrid, at least one steam turbine, and/or at least one electric vehicle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is related to and claims priority from the following US patents and patent applications: this application is a continuation-in-part of U.S. patent application Ser. No. 18/627,004, filed Apr. 4, 2024, which claims priority from and the benefit of U.S. Provisional Patent Application No. 63/458,805, filed Apr. 12, 2023. Each of the above-mentioned applications is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to power conversion systems, and more specifically to multiport, modular power conversion systems capable of connecting to multiple energy sources and/or multiple power consuming nodes simultaneously. 2. Description of the Prior Art It is generally known in the prior art to provide AC/DC converters, DC/AC inverters, DC/DC converters and other means for connecting power sources to power consuming devices. Prior art patent documents include the following: U.S. Patent Publication No. 20210408937 for MMC submodules scale-up methodology for mv and hv power conversion system applications by inventors Bhattacharya, et al., filed Jun. 24, 2021 and published Dec. 30, 2021, is directed to modular multilevel converter (MMC) scale-up control methodologies which can be applied for MV and HV DC applications. In one example, an MMC includes first and second legs each with submodule (SM) groups connected in series, where each SM group includes a plurality of SMs; local group controllers that can control a corresponding SM group; and a central controller that can control output voltage of the MMC via the local group controllers. The local group controllers can provide capacitor voltage balancing (CVB) control of corresponding SM groups. WIPO Publication No. 2022103858 for Multiport energy routing systems by inventors Mauger, et al., filed Nov. 10, 2021 and published May 19, 2022, is directed to a flexible multiport energy routing system including a first port configured to connect to an AC grid, a plurality of second ports configured to connect to a plurality of devices, a step-down transformer, a power converter stack, and a third port. The step-down transformer can have a high voltage side electrically coupled to the first port and a low voltage side. The power converter stack can comprise a plurality of power converter modules each having a first converter bridge connected to the low voltage side of the step-down transformer and a second converter bridge connected to one or more of the plurality of second ports. Each of the power converter modules can have a converter transformer connected between the first and second converter bridges. The first and second converter bridges can bidirectionally manage AC and DC power flows between the first, second, and third ports. U.S. Pat. No. 11,196,338 for Semiconductor topologies and devices for soft starting and active fault protection of power converters by inventors Beddingfield, et al., filed Dec. 29, 2018 and issued Dec. 7, 2021, is directed to semiconductor topologies and devices that can be used for soft starting and active fault protection of power converters. In one example, an active switch device includes an active switch having a gating control input; and a thyristor having a gating control input. The thyristor is coupled in parallel with the active switch. The active switch can be an IGBT, MOSFET, or other appropriate device. In another example, a power converter can include the active switch devices and switching control circuitry coupled to gating control inputs of the active switch devices. U.S. Patent Publication No. 20210012944 for Transformer designs for very high isolation with high coupling by inventors Beddingfield, et al., filed Jul. 8, 2020 and published Jan. 14, 2021, is directed to transformer designs that offer very high isolation while maintaining high coupling between the windings. In one example, an isolation transformer includes a first excitation coil wound around a first core and a second excitation coil wound about a second core. The second core is electrically separated from the first core by a high resistivity magnetic material or a non-conductive material. The first and second cores can include corresponding core segments arranged in a trident geometry or a quindent geometry. The core segments can align when the first excitation coil is inserted into a void of the second excitation coil. The isolation transformer designs are mechanically separable which can result in safe, energized, plug operations. U.S. Pat. No. 10,734,914 for Fault-tolerant controller for modular multi-level converters by inventors Azidehak, et al., filed Sep. 26, 2019 and issued Aug. 4, 2020, is directed to fault-tolerant controller architectures for multi-level converters. In one example, a multi-level converter includes an array of power modules. The power modules can include a controller communicatively coupled to controllers of