Patent Publication Number: US-2021184597-A1

Title: Grid-connected power conversion system and control method thereof

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The present application claims priority to Korean Patent Application No. 10-2019-0168690, filed Dec. 17, 2019, the entire contents of which is incorporated herein for all purposes by this reference. 
     BACKGROUND 
     1. Technical Field 
     The present disclosure relates to a grid-connected power conversion system and a control method thereof, and more particularly, to a grid-connected power conversion system in which a replacement cycle of a fuel cell stack can be extended by switching a voltage inputted to a multi-input transformer, when the performance of the fuel cell stack deteriorates due to continuous use thereof and thereby a DC voltage outputted therefrom drops, and a control method thereof. 
     2. Description of the Related Art 
     The demand for energy is increasing continuously and rapidly. For fossil energy, which has been used as a main energy source from the past to the present, regulations have been strengthened internationally due to the issues about environmental pollution occurring in a power generation process. 
     In order to overcome this problem, alternative energy has continuously been developed. New regeneration energy sources including solar cells are spotlighted as next generation alternative energy sources in that it is not required to use limited fossil fuels and environmental pollution can be minimized. Unlike solar power generation, wind power generation, and the like, fuel cells are attracting a lot of attention as clean energy capable of stably supplying electric power regardless of the surrounding environments. 
     However, the fuel cell essentially requires a power conversion device for use as a regular power source due to its low cell voltage. A conventional power conversion device converts a DC voltage outputted from a fuel cell stack into an AC voltage through an inverter, and boosts the converted AC voltage to an appropriate high voltage to supply electric power to an electric power grid. 
     The conventional power conversion device uses the fuel cell until the fuel cell is capable of supplying a reference voltage into which the voltage from the fuel cell may be converted as a voltage to be supplied to the grid. Once a voltage lower than or equal to the reference voltage is outputted, the fuel cell is replaced. When the DC voltage outputted from the fuel cell drops and the inverter is not capable of converting the voltage to output the reference voltage, the fuel cell is replaced. Accordingly, there is a need for development of a grid-connected power conversion system in which a lifespan of the fuel cell can be extended to reduce the number of replacement cycles in terms of energy management. 
     The contents described as the related art have been provided only to assist in understanding the background of the present disclosure and should not be considered as corresponding to the related art known to those having ordinary skill in the art. 
     SUMMARY 
     An object of the present disclosure is to provide a grid-connected power conversion system in which a fuel cell stack can be additionally used by switching a voltage inputted to a multi-input transformer and changing a grid voltage, when the performance of the fuel cell stack deteriorates due to the use thereof, and a control method thereof. 
     According to an embodiment of the present disclosure, a grid-connected power conversion system includes a fuel cell stack generating a DC voltage, a power conversion system (PCS) converting the DC voltage supplied from the fuel cell stack into an AC voltage, a multi-input transformer including a primary coil having a plurality of voltage input terminals and a secondary coil transforming a magnitude of the voltage applied to the primary coil and outputting the transformed voltage, the plurality of voltage input terminals determining the number of turns of the primary coil differently from each other, one of the plurality of voltage input terminals receiving the AC voltage converted in the PCS, and a controller selecting the one of the plurality of voltage input terminals of the multi-input transformer based on the magnitude of the DC voltage generated from the fuel cell stack and determining whether to replace the fuel cell stack. 
     The grid-connected power conversion system may further include a DC voltage sensor measuring the DC voltage outputted from the fuel cell stack, and an AC voltage sensor measuring the AC voltage outputted from the PCS. The voltages measured by the DC voltage sensor and the AC voltage sensor may be transmitted to the controller, and the controller may receive measurement values. 
     When the DC voltage received from the DC voltage sensor is lower than or equal to a minimum DC voltage required for conversion into a preset reference voltage, the controller may switch the voltage inputted to the voltage input terminal of the multi-input transformer. 
     When the DC voltage outputted from the fuel cell stack is lower than or equal to a minimum DC voltage required for conversion into a preset reference voltage, the AC voltage outputted from the PCS may be changed to a preset threshold voltage. 
     When the DC voltage measured by the DC voltage sensor is lower than or equal to a minimum DC voltage required for conversion into a preset threshold voltage, the controller may determine to stop operation of the fuel cell stack and replace the fuel cell stack. 
     The PCS may include an inverter converting the DC voltage into the AC voltage, a filter removing harmonic components contained in the AC voltage; and a grid protector detecting a failure in an electric power grid and blocking a failure section. 
     The controller may include a central controller monitoring and controlling performance of the fuel cell stack, and a PCS controller monitoring and controlling the AC voltage outputted from the PCS, and control operation of the fuel cell stack and the AC voltage. 
     The fuel cell stack may be configured as a module-type fuel cell stack in which a plurality of fuel cells are arranged in parallel, each module being independently controllable. 
     According to another embodiment of the present disclosure, a control method of the grid-connected power conversion system includes a fuel cell stack operating step in which the DC voltage is outputted from the fuel cell stack, the DC voltage is converted into the AC voltage by the PCS, the converted AC voltage is supplied to a grid, and the DC voltage and the AC voltage are monitored by the controller; a switch determining step in which the DC voltage is compared with a minimum DC voltage required for conversion into a preset reference voltage and it is determined whether to make a switch in the multi-input transformer and whether to change the AC voltage outputted from the PCS, a voltage changing step in which operation of the fuel cell stack is stopped, the voltage to be inputted to the voltage input terminal of the multi-input transformer is switched to a preset threshold voltage, and the AC voltage to be outputted from the PCS is changed to the threshold voltage, a fuel cell stack operation restarting step in which the operation of the fuel cell stack is restarted using the threshold voltage as a grid voltage, and the DC voltage and the AC voltage are monitored by the controller, a fuel cell stack replacement determining step in which the DC voltage is compared with a minimum DC voltage required for conversion into the threshold voltage and it is determined whether to replace the fuel cell stack, and an after-replacement fuel cell stack operating step in which the fuel cell stack is replaced and then the grid-connected power conversion system is operated with the replaced fuel cell stack as in the fuel cell stack operating step. 
     In the switch determining step, it may be determined to continuously operate the fuel cell stack without making any switch when the DC voltage is higher than the minimum DC voltage required for conversion into the reference voltage, and it may be determined to make a switch in the multi-input transformer when the DC voltage is lower than or equal to the minimum DC voltage required for conversion into the reference voltage. 
     In the fuel cell stack replacement determining step, it may be determined to continuously operate the fuel cell stack when the DC voltage is higher than the minimum DC voltage required for conversion into the threshold voltage, and it may be determined to stop the operation of the fuel cell stack and replace the fuel cell stack when the DC voltage is lower than or equal to the minimum DC voltage required for conversion into the threshold voltage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a view illustrating an overall configuration of a grid-connected power conversion system according to an embodiment the present disclosure. 
         FIG. 2  is a flowchart of a control method of a grid-connected power conversion system according to an embodiment of the present disclosure. 
         FIG. 3  is a graph illustrating an effect of a grid-connected power conversion system according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Specific structural or functional descriptions of embodiments of the present disclosure disclosed in the present specification or application are merely given for the purpose of describing embodiments according to the present disclosure. Embodiments according to the present disclosure may be implemented in various forms and are not to be construed as being limited to the embodiments described in the present specification or application. 
     Terms used in the present specification are used only for describing specific embodiments, and not intended to limit the present disclosure. Unless the context clearly indicates otherwise, singular expressions include plural expressions. It should be further understood that the term “include”, “have”, or the like in the present specification is used to denote the existence of the stated features, numbers, steps, operations, elements, parts, or combinations thereof, while not precluding the existence or addition of one or more other features, numbers, steps, operations, elements, parts, or combinations thereof. 
     Unless defined otherwise, all terms used herein, including technical and scientific terms, have the same meaning as commonly understood by those having ordinary skill in the art to which the present disclosure pertains. Terms such as those defined in generally used dictionaries should be interpreted to have meanings consistent with the contextual meanings in the relevant art, and are not to be interpreted to have ideal or excessively formal meanings unless clearly defined in the present specification. 
     Hereinafter, the present disclosure will be described in detail by describing preferred embodiments of the present disclosure with reference to the accompanying drawings. Identical reference marks shown in each drawing are used to denote identical elements. 
     The present disclosure relates to a grid-connected power conversion system and a control method thereof. According to the present disclosure, a voltage inputted to a grid can be changed depending on performance of a fuel cell stack  100  to increase a section in which the fuel cell stack  100  is usable, such that the replacement costs of the fuel cell stack  100  can be reduced. 
       FIG. 1  is a view illustrating an overall configuration of a grid-connected power conversion system according to an embodiment the present disclosure. 
     Referring to  FIG. 1 , the grid-connected power conversion system according to an embodiment of the present disclosure may include a fuel cell stack  100 , a power conversion system (PCS)  200 , a multi-input transformer  300 , and a controller  400 . 
     The fuel cell stack  100  generates a DC voltage and supplies the generated DC voltage to the PCS  200 . The fuel cell stack  100  may be configured as a fuel cell stack  100  producing electric power using hydrogen, and is not particularly limited in the present disclosure. 
     The PCS  200 , which is a device converting the DC voltage supplied from the fuel cell stack  100  into an AC voltage, may function to supply high-quality electric power to a grid based on the AC voltage converted through a filter  220  and a grid protector  230 . 
     The PCS  200  may include an inverter  210  converting a DC voltage into an AC voltage, a filter  220  removing harmonic components contained in the AC voltage, and a grid protector  230  protecting and monitoring the grid. 
     The multi-input transformer  300  functions to boost the AC voltage supplied from the PCS  200  to a predetermined high voltage to transmit electric power to the grid. In general, the voltage is transformed to an ultra-high voltage of  22 . 9  kV and the transformed voltage is supplied for home and industrial use through the power supply gird. 
     As illustrated in  FIG. 1 , the multi-input transformer  300  may include a plurality of voltage input terminals  310 .  FIG. 1  illustrates a three-phase three-wire dual input transformer. The voltage input terminal  310  may be connected to a primary coil  320 . One of the plurality of voltage input terminals  310  may be selected depending on the situation, and the multi-input transformer  300  may include a secondary coil  330  transforming a magnitude of the voltage applied to the primary coil  320  and outputting the transformed voltage. 
     The number of turns of the primary coil  320  may be determined differently depending on the voltage inputted to the selected voltage input terminal  310  to keep the voltage outputted through the secondary coil  330  constant. The AC voltage converted in the PCS  200  may be inputted to one of the plurality of voltage input terminals  310 . 
     When the output voltage converted through the inverter  210  is lower than or equal to a reference voltage according to the use of the fuel cell stack  100 , a conventional grid-connected power conversion system has a problem in that the fuel cell stack  100  should be replaced to operate the system. Therefore, when the output voltage generated from the fuel cell stack  100  and converted through the inverter  210  is lower than or equal to the reference voltage, the fuel cell stack  100  is no longer usable. That is, the fuel cell stack  100  has a short lifespan and a short replacement cycle. 
     In contrast, in the present disclosure including the multi-input transformer  300  having a plurality of voltage input terminals  310 , when the output voltage of the fuel cell stack  100  is lower than or equal to the reference voltage, the voltage inputted to the voltage input terminal  310  is switched, thereby extending a section in which the fuel cell stack  100  is usable. That is, when the performance of the fuel cell stack  100  deteriorates and thereby the fuel cell stack  100  outputs a voltage lower than or equal to the reference voltage, the fuel cell stack  100  is conventionally replaced to operate the system. In contrast, in the present disclosure, even though the fuel cell stack  100  outputs a DC voltage lower than or equal to the reference voltage, the fuel cell stack  100  may further be utilized by switching the voltage inputted to the multi-input transformer  300  having a plurality of voltage input terminals  310  and then boosting the switched voltage. 
     The multi-input transformer  300  may be connected to the grid to supply electric power. The grid may be a provider operating an electric power grid and supplying electric power based on the electric power grid such as Korea Electric Power Corporation, or another power supply source operating an independent power transmission and distribution system. 
     The controller  400  may function to control the overall operation of the grid-connected power conversion system. The controller  400  may select and switch a voltage inputted to the voltage input terminal  310  of the multi-input transformer  300  based on a magnitude of the DC voltage generated from the fuel cell stack  100 . In addition, the controller  400  may determine whether to replace the fuel cell stack  100 . 
     The controller  400  may include a central controller monitoring and controlling the performance of the fuel cell stack  100 , and a PCS controller monitoring and controlling the AC voltage outputted from the PCS  200 . 
     In addition, the grid-connected power conversion system according to an embodiment of the present disclosure may include a DC voltage sensor  510  and an AC voltage sensor  520 . 
     The DC voltage sensor  510  may measure the DC voltage outputted from the fuel cell stack  100  and transmit the measured voltage to the controller  400 . In addition, the AC voltage sensor  520  may measure the AC voltage outputted from the PCS  200  and transmit the measured voltage to the controller  400 . 
     The controller  400  may receive the voltages measured by the DC voltage sensor  510  and the AC voltage sensor  520 , monitor the performance of the fuel cell stack  100  through the central controller, and continuously operate the fuel cell stack  100  or stop the operation of the fuel cell stack  100 . Further, the controller  400  may control the PCS  200  through the PCS controller to adjust the converted AC voltage. In addition, the controller  400  may control the multi-input transformer  300  to switch the voltage inputted to the voltage input terminal  310 . 
     The controller  400  may compare the DC voltage received from the DC voltage sensor  510  with a minimum DC voltage required for conversion into the preset reference voltage. When the received DC voltage is higher than the minimum DC voltage required for conversion into the reference voltage, the controller  400  controls the fuel cell stack  100  to be continuously operated. 
     If the fuel cell stack  100  is operated continuously, the performance of the fuel cell stack  100  deteriorates and the outputted DC voltage continuously drops. When the DC voltage received from the DC voltage sensor  510  is lower than or equal to the minimum DC voltage required for conversion into the preset reference voltage, the controller  400  may switch the voltage inputted to the voltage input terminal  310  of the multi-input transformer  300 . When the voltage inputted to the voltage input terminal  310  is switched, the number of turns of the primary coil  320  is changed, thereby additionally using the fuel cell stack  100  while keeping the voltage supplied to the grid constant. In this case, the switched voltage is a threshold voltage. That is, the fuel cell stack  100  may be additionally used until the DC voltage outputted from the fuel cell stack  100  reaches the minimum DC voltage required to be the threshold voltage. 
     In an embodiment for specific description where the reference voltage may be preset in two modes, i.e. RMS 380 V and RMS 340 V, the PCS  200  is set to convert the DC voltage into the AC voltage of RMS 380 V, and the voltage input terminal  310  of the multi-input transformer  300  is set to receive 380 V for operation. When the AC voltage converted and outputted from the PCS  200  is RMS 380 V or more, the controller  400  may control the fuel cell to be continuously operated. 
     When the fuel cell stack  100  is continuously operated and the AC voltage is lower than or equal to RMS 380 V, the controller  400  may switch the voltage inputted to the voltage input terminal  310  of the multi-input transformer  300  to  340 V, which is a threshold voltage. The operation of the fuel cell stack  100  may be temporarily stopped before the switch. In addition, the AC voltage outputted from the PCS  200  may be adjusted to RMS 340 V by the PCS controller. The AC voltage may be changed by adjusting the switching speed of the PCS  200 . Thereafter, the central controller may control the fuel cell stack  100  to restart the operation thereof. 
     According to the conventional system, it is necessary to replace the fuel cell stack  100  when the DC voltage outputted from the fuel cell stack  100  is lower than or equal to a minimum DC voltage required for conversion into RMS 380 V. In contrast, according to the present disclosure, the fuel cell stack  100  may be additionally used until the DC voltage outputted from the fuel cell stack  100  reaches a minimum DC voltage required for conversion into RMS 340 V by switching over the voltage input terminal  310  of the multi-input transformer  300 . 
     Meanwhile, when the DC voltage outputted from the fuel cell stack  100  is lower than or equal to the minimum DC voltage required for conversion into RMS 340 V, the controller  400  may determine to stop the operation of the fuel cell stack  100  and replace the fuel cell stack  100 . 
     In addition, the fuel cell stack  100  may be configured as a fuel cell stack  100  in a module type including a plurality of fuel cells. The fuel cell stack  100  modules may be arranged in parallel, each module being independently controllable. The conventional power conversion device, which is in a single input single output (SISO) type, has problems in that when a failure occurs in one of the fuel cell stacks  100 , the entire device is shut down, and it is difficult to control individually the fuel cell stacks  100 . In contrast, the module-type fuel cell stacks  100  arranged in parallel, which are in a multi input single output (MISO) type, have advantageous effects in that it is possible to control independently each of the fuel cell stack  100  modules, thereby making it easy to individually maintain the fuel cell stack  100  modules. 
       FIG. 2  is a flowchart of a control method of the grid-connected power conversion system according to an embodiment of the present disclosure. 
     Referring to  FIG. 2 , the control method of a grid-connected power conversion system according to an embodiment of the present disclosure may include a fuel cell stack operating step (S 100 ), a switch determining step (S 200 ), a voltage changing step (S 300 ), and a fuel cell stack operation restarting step (S 400 ), a fuel cell stack replacement determining step (S 500 ), and an after-replacement fuel cell stack operating step (S 600 ). 
     In the fuel cell stack operating step (S 100 ), a DC voltage is outputted from the fuel cell stack  100 , the outputted DC voltage is converted into an AC voltage in the PCS  200 , the converted AC voltage is supplied to the grid. In the fuel cell stack operating step (S 100 ), the DC voltage and AC voltage are continuously monitored by the controller  400 . 
     In the switch determining step (S 200 ), the monitored DC voltage is compared with the minimum DC voltage required for conversion into the preset reference voltage. When the DC voltage outputted from the fuel cell stack  100  is higher than the minimum DC voltage required for conversion into the preset reference voltage, the controller  400  controls the fuel cell stack  100  to be continuously operated. Otherwise, the next voltage changing step is performed. Here, the reference voltage may be set as RMS 380 V. 
     In the voltage changing step (S 300 ), the voltage inputted to the voltage input terminal  310  of the multi-input transformer  300  is switched when the DC voltage outputted from the fuel cell stack  100  is lower than or equal to the minimum DC voltage required for conversion into the preset reference voltage. The controller  400  switches the voltage inputted to the voltage input terminal  310  to a preset threshold voltage and adjusts the AC voltage converted in the PCS  200  to the threshold voltage. Here, the threshold voltage may be set as 340 V. 
     The fuel cell stack operation restarting step (S 400 ) is a step in which the grid-connected power conversion system is operated using the threshold voltage changed after the voltage changing step (S 300 ) as a grid voltage. In the fuel cell stack operation restarting step (S 400 ), the DC voltage and the AC voltage are continuously monitored by the controller  400 . 
     In the fuel cell stack replacement determining step (S 500 ), the monitored DC voltage is compared with the minimum DC voltage required for conversion into the preset threshold voltage. When the DC voltage outputted from the fuel cell stack  100  is higher than the minimum DC voltage required for conversion into the preset threshold voltage, the controller  400  controls the fuel cell stack  100  to be continuously operated. Otherwise, the next after-replacement fuel cell stack operating step (S 600 ) is performed. 
     The after-replacement fuel cell stack operating step (S 600 ) is a step in which the fuel cell stack  100  is operated after being replaced when the DC voltage outputted from the fuel cell stack  100  is lower than or equal to the minimum DC voltage required for conversion into the preset threshold voltage. In the after-replacement fuel cell stack operating step (S 600 ), the operation of the previous fuel cell stack  100  is stopped, and a new fuel cell stack  100  is replaced and then operated. 
       FIG. 3  is a graph illustrating an effect of the grid-connected power conversion system according to an embodiment of the present disclosure. 
     Referring to  FIG. 3 , it may be verified that the grid-connected power conversion system according to an embodiment of the present disclosure is capable of additionally using the fuel cell stack  100  by changing a grid voltage, when the performance of the fuel cell stack  100  deteriorates and the fuel cell stack  100  outputs a DC voltage lower than or equal to the minimum DC voltage required for conversion into the reference voltage. 
     Referring to the example illustrated in  FIG. 3 , a minimum DC voltage required for outputting the grid voltage may be set. As the fuel cell stack  100  is continuously used, its performance deteriorates. When the performance deteriorates to a certain level, the fuel cell stack  100  ultimately outputs the minimum DC voltage required for conversion into the reference voltage in the PCS  200 . 
     At this time, the grid-connected power conversion system according to the present disclosure may switch over the voltage input terminal  310  of the multi-input transformer  300  with the threshold voltage. The controller  400  adjusts the AC voltage outputted from the PCS  200  to the threshold voltage so as to continuously operate the grid-connected power conversion system. The fuel cell stack  100  may be additionally used until the fuel cell stack  100  reaches the minimum DC voltage required for conversion into the threshold voltage. If there is no further switch in the multi-input transformer  300 , the fuel cell stack  100  may be additionally utilized until the performance thereof deteriorates to the certain level after the switch, although the fuel cell stack  100  should be replaced at a time when the performance of the fuel cell stack  100  deteriorates to the certain level. The additional utilization section illustrated in  FIG. 3  refers to a section where the fuel cell stack  100  may be additionally used resulting from the switch. 
     According to the grid-connected power conversion system and the control method thereof of the present disclosure, even though the output from the fuel cell stack deteriorates, it is possible to additionally utilize the fuel cell stack by switching the voltage inputted to the multi-input transformer, thereby extending a section in which the fuel cell stack is usable and efficiently managing energy. 
     In addition, it is possible to increase the lifespan of the fuel cell stack and extend the replacement cycle, thereby reducing the costs for replacing the fuel cell stack. 
     Therefore, the utilization section of the fuel cell increases to some extent to reduce the number of replacements of the fuel cell stack  100 , such that the costs can be reduced. In various grid systems, the fuel cell stack  100  may be additionally used by making a switch in the multi-input transformer  300 . Thus, the grid-connected power conversion system according to the present disclosure is applicable to various systems. 
     Although the present disclosure has been shown and described with respect to specific embodiments, it will be apparent to those having ordinary skill in the art that the present disclosure may be variously modified and altered without departing from the spirit and scope of the present disclosure as defined by the following claims.