An ac to dc high efficiency constant voltage converter circuit
By using a high-efficiency AC-to-DC constant voltage converter circuit, and employing dual-tube modules and multi-parameter monitoring, the problem of downtime and circuit damage caused by single-module failures in the production line control cabinet was solved. This enabled fault self-diagnosis and modular design, improving the reliability and ease of maintenance of the production line.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHENMA BOLIEMAI PINGDINGSHAN AIR BAG YARN MFG CO LTD
- Filing Date
- 2025-06-05
- Publication Date
- 2026-07-28
AI Technical Summary
When the existing production line control cabinet is powered by a DC power supply, a single module failure can cause the entire production line to shut down. Furthermore, the failure rate of circuit damage and short circuit fires caused by individual switching transistors being turned on is high, making maintenance complex.
It adopts a high-efficiency AC-to-DC constant voltage converter circuit, utilizes a dual-transistor module to conduct simultaneously, and combines transformer, rectifier, power conversion and filter modules to provide multi-parameter monitoring and fault self-diagnosis functions. The modular design supports hot-swapping.
It reduces the failure rate, ensures that a single failure only affects a single machine, provides intuitive fault indications, simplifies maintenance, and improves the reliability and stability of the system.
Smart Images
Figure CN224571101U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of constant voltage converter technology, specifically to a high-efficiency AC-to-DC constant voltage converter circuit. Background Technology
[0002] The current production line control cabinet uses DC power supply. One DC power supply supports two production lines. If a module or battery pack fails, both production lines will stop and production will be impossible. Moreover, the repair is complicated.
[0003] Furthermore, the current method of individually turning on the switching transistors leads to a high failure rate of faults such as short circuits and fires caused by circuit damage.
[0004] Therefore, developing a fuse device with multi-parameter monitoring and fault self-diagnosis functions is of great significance for improving the reliability and stability of power systems. Utility Model Content
[0005] To address the above problems, this invention provides a high-efficiency AC-to-DC constant voltage converter circuit, which solves the aforementioned issues.
[0006] To achieve the above objectives, this utility model provides the following technical solution: an AC to DC high-efficiency constant voltage converter circuit, including a control cabinet and a circuit board installed in the control cabinet, the circuit board being provided with a conversion module, the conversion module including an input module, the input module being connected in series with a capacitor module, and the capacitor module being connected in series with a dual-tube module;
[0007] The dual-tube module is connected in series with a transformer module, which includes a primary winding and a secondary winding. The dual-tube module is connected in series with the primary winding.
[0008] The secondary winding is connected in series with a rectifier module, the rectifier module is connected in series with a power conversion module, the power conversion module is connected in series with a filter module, and the filter module is connected in series with an output module.
[0009] Preferably, the input module receives a 220V AC power supply, and the capacitor module rectifies the power supply received by the input module to obtain a 310V DC power supply.
[0010] Preferably, the transformer module performs high-frequency conversion of electrical energy through primary winding and secondary winding.
[0011] Preferably, the rectifier module regulates the DC power supply.
[0012] Preferably, the power conversion module converts electrical energy into magnetic energy for storage.
[0013] Preferably, the filtering module filters out high-frequency noise and electromagnetic interference signals in the power supply, providing a clean and stable DC power supply for electronic devices.
[0014] Preferably, the output module is welded to an external load.
[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0016] 1. This application uses a dual-transistor module to simultaneously turn the switching transistors on and off, which avoids the short circuit and fire caused by single-transistor circuit damage. It has a low failure rate and is safe in case of failure. In addition, it adopts a split layout to replace the original DC power supply, and provides feedback to the warning light when the whole system fails, which is intuitive and more convenient for maintenance personnel to directly confirm.
[0017] 2. When this application is used in the control cabinet of the production line, if a fault occurs in a certain place, it will only affect one machine and will not affect all production lines. Moreover, the fault point is directly indicated by a warning light, making replacement convenient. In addition, this design is modular and supports hot-swapping. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the control cabinet structure of this utility model;
[0019] Figure 2 This is a schematic diagram of the overall structure of this utility model;
[0020] Figure 3 This is a schematic diagram of the overall top view structure of this utility model;
[0021] Figure 4 This is a schematic diagram of the main circuit structure of this utility model.
[0022] The diagram is labeled as follows: 1. Control cabinet; 2. Circuit board; 3. Conversion module; 4. Input module; 5. Capacitor module; 6. Dual-tube module; 7. Transformer module; 8. Rectifier module; 9. Power conversion module; 10. Filtering module; 11. Output module. Detailed Implementation
[0023] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model.
[0024] Please see Figures 1 to 3A high-efficiency AC-to-DC constant voltage converter circuit includes a control cabinet 1 and a circuit board 2 disposed in the control cabinet 1. The control cabinet 1 is located on one side of the production line and is used to control the operation of the entire production line. Both the control cabinet 1 and the circuit board 2 are well-known technologies and are currently very mature. Those skilled in the art can and should understand their specific functions and structures, so they will not be described in detail here. The circuit board 2 is provided with a conversion module 3, which includes an input module 4. The input module 4 is connected in series with a capacitor module 5, and the capacitor module 5 is connected in series with a dual-transistor module 6. Block 6 includes two switching transistors. The circuit is connected to the core driver board via pins. AC220V enters the input module 4 and is rectified into 310V DC power by the capacitor module 5. During this period, the power is controlled by the core driver board through the dual-transistor module 6 and further regulated and rectified by the rectifier module 8 before being turned on to the power conversion module 9. The power conversion module 9 is turned on at a certain frequency (65KHZ-100KHZ) with a duty cycle of 0%-45% to achieve high-efficiency power conversion. The converted electromotive force is filtered by the filter module 10 and then supplied to the load through the output module 11.
[0025] It should be further added that a feedback circuit is installed in parallel on the output module 11. The feedback circuit constantly feeds back the current output status (voltage, circuit parameters, etc.) to the core driver board. The current output voltage and current will be fed back to the core driver board in several cycles (65KHZ as an example). The control circuit will adjust the switching time ratio of the current conversion circuit to achieve the purpose of balancing voltage and current. Each cycle is compared in real time to get infinitely close to the preset voltage value.
[0026] The dual-tube module 6 is connected in series with the transformer module 7, which includes a primary winding and a secondary winding. The dual-tube module 6 is connected in series with the primary winding.
[0027] The secondary winding is connected in series with a rectifier module 8, the rectifier module 8 is connected in series with a power conversion module 9, the power conversion module 9 is connected in series with a filter module 10, and the filter module 10 is connected in series with an output module 11.
[0028] Please see Figure 4 The specific circuit operation is as follows:
[0029] In this circuit, C1 is the capacitor module 5 for the input DC power supply, Q1 and Q2 are the two switching transistors of the dual-transistor module 6, D1 and D2 are the diodes for flux reset of the transformer module 7, T1 is the transformer module 7, D3 and D4 are the output rectifier and freewheeling diodes, and L1, C2, and R1 are the power conversion module 9, the filter module 10 (output filter capacitor), and the load, respectively. When the primary switching transistors Q1 and Q2 are simultaneously turned on by the core driver board, energy is transferred from the primary side of the transformer module 7 to the secondary side. In the secondary side, the rectifier diode D3 is turned on, transferring energy from the transformer module 7 to L1, the power conversion module 9, the filter module 10 (output filter capacitor), and the load. When the primary switching transistors Q1 and Q2 are simultaneously turned off, the excitation current of the transformer module 7 flows through the forward-biased D1 and D2 and back to the power supply until all the excitation energy of the primary side and the energy stored in the leakage inductance return to the input power supply. In the secondary side, the freewheeling diode D4 is turned on, transferring the energy of the L1 inductor to the load.
[0030] Input module 4 receives 220V AC power, and capacitor module 5 rectifies the power input from input module 4 to obtain 310V DC power.
[0031] Transformer module 7 performs high-frequency conversion of electrical energy through its primary and secondary windings. Transformer module 7 has an energy storage and release circuit, eliminating the need for a separate reset circuit or reset winding. The main reason is that transformer module 7 is energized when the switching transistor is on, and when the switching transistor is closed, the two diodes on the bridge arm provide freewheeling current, the magnetic core is demagnetized, and the energy from the magnetic core returns to the DC power supply.
[0032] It should be noted that, compared to other multi-transistor converter topologies, there is no risk of shoot-through short circuit between the two switching transistors. This is because the two switching transistors are on opposite sides of the bridge. During normal operation, both transistors are turned on and off simultaneously. At this time, the primary winding of transformer module 7 bears the voltage, so there is no risk of shoot-through.
[0033] Moreover, unlike traditional dual-transistor forward power supplies, this application does not require an isolation drive transformer module 7. Instead, it has a core drive board that directly drives the two switching transistors, saving materials and space. The control signal is more complete and will not cause product differences due to different batches of isolation drive.
[0034] The rectifier module 8 regulates the DC power supply.
[0035] The power conversion module 9 converts electrical energy into magnetic energy for storage.
[0036] The filter module 10 filters out high-frequency noise and electromagnetic interference signals in the power supply, providing a clean and stable DC power supply for electronic devices.
[0037] Output module 11 is soldered to an external load.
[0038] When using this utility model:
[0039] First, the control cabinet 1 is located on one side of the production line and is used to control the operation of the entire production line. The dual-tube module 6 includes two switching tubes. The core driver board is connected to the circuit through pins. After AC220V enters the input module 4, it is rectified into 310V DC power by the capacitor module 5. During this period, the power is controlled by the core driver board through the dual-tube module 6 and further regulated and rectified by the rectifier module 8 to conduct to the power conversion module 9. The power conversion module 9 conducts at a certain frequency (65KHZ-100KHZ) with a duty cycle of 0%-45% to achieve high-efficiency power conversion. The converted electromotive force is filtered by the filter module 10 and then supplied to the load through the output module 11.
[0040] Secondly, a feedback circuit is installed in parallel on the output module 11. The feedback circuit constantly feeds back the current output status (voltage, circuit parameters, etc.) to the core driver board. The current output voltage and current will be fed back to the core driver board in several cycles (65KHZ as an example). The control circuit will adjust the switching time ratio of the current conversion circuit to achieve the purpose of balancing voltage and current. Each cycle is compared in real time to get infinitely close to the preset voltage value.
[0041] Then, the specific circuit operation is as follows: C1 is the capacitor module 5 for input DC power supply, Q1 and Q2 are the two switching transistors of the dual-transistor module 6, D1 and D2 are the diodes for flux reset of transformer module 7, T1 is transformer module 7, D3 and D4 are the diodes for output rectification and freewheeling, and L1, C2 and R1 are the power conversion module 9, the filter module 10 (output filter capacitor) and the load, respectively.
[0042] Finally, when the primary switching transistors Q1 and Q2 are simultaneously turned on by the core driver board, energy is transferred from the primary side of transformer module 7 to the secondary side. In the secondary side, rectifier diode D3 is turned on, transferring energy from transformer module 7 to L1, power conversion module 9, C2 filter module 10 (output filter capacitor), and the load. When the primary switching transistors Q1 and Q2 are simultaneously turned off, the excitation current of transformer module 7 flows through the forward-biased D1 and D2 and back to the power supply until all the excitation energy of the primary side and the energy stored in the leakage inductance return to the input power supply. In the secondary side, freewheeling diode D4 is turned on, transferring energy from L1 inductor to the load.
[0043] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A high-efficiency constant voltage converter circuit for AC to DC, comprising a control cabinet (1) and a circuit board (2) disposed in the control cabinet (1), wherein the circuit board (2) is provided with a conversion module (3), characterized in that: The conversion module (3) includes an input module (4), the input module (4) is connected in series with a capacitor module (5), and the capacitor module (5) is connected in series with a dual-tube module (6); The dual-tube module (6) is connected in series with a transformer module (7), the transformer module (7) includes a primary winding and a secondary winding, and the dual-tube module (6) is connected in series with the primary winding; The secondary winding is connected in series with a rectifier module (8), the rectifier module (8) is connected in series with a power conversion module (9), the power conversion module (9) is connected in series with a filter module (10), and the filter module (10) is connected in series with an output module (11).
2. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The input module (4) inputs a 220V AC power supply, and the capacitor module (5) rectifies the power input from the input module (4) to obtain a 310V DC power supply.
3. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The transformer module (7) performs high-frequency conversion of electrical energy through the primary winding and the secondary winding.
4. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The rectifier module (8) regulates the DC power supply.
5. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The power conversion module (9) converts electrical energy into magnetic energy for storage.
6. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The filtering module (10) filters out high-frequency noise and electromagnetic interference signals in the power supply, providing a clean and stable DC power supply for electronic devices.
7. The AC-to-DC high-efficiency constant voltage converter circuit according to claim 1, characterized in that: The output module (11) is welded to an external load.