AC to DC Power Converter with Zero-Crossing Gating
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Solution Overview
Problem
Conventional systems for converting high voltage AC to low voltage DC are hindered by the need for large high voltage filter capacitors and switching power supplies, which increase size, cost, and power consumption, making them unsuitable for space-constrained applications like solid-state electricity metering and grid automation devices.
Innovation Solution
A method and apparatus that utilize a rectifier to convert high voltage AC to full wave DC, followed by a gating component that turns on at zero crossing and off when the voltage exceeds a preset threshold, feeding an intermediate voltage to a DC-DC converter to produce a high current, low voltage DC output, reducing the rating and size of DC-DC converter components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional switching power supplies are used to convert high voltage AC to low voltage DC, then the conversion function is achieved, but large high voltage filter capacitors and switching power supply components are required, increasing size and cost
Solution Approach 1:
The power conversion process is divided into two separate stages: first, a rectifier converts AC to high voltage DC; second, a DC-DC converter steps down to low voltage DC. This segmentation allows each component to be optimized independently, eliminating the need for large high voltage capacitors in the final stage.
Solution Approach 2:
The patent introduces an intermediate high voltage DC stage as a mediator between the AC input and the low voltage DC output. This intermediary allows the use of a simple rectifier followed by a low voltage DC-DC converter, avoiding the need for large components that would be required if converting directly from high voltage AC.
2Stability of the object's composition
If large high voltage filter capacitors are used in switching power supplies, then voltage ripple is reduced, but the physical size and cost of the power supply increases
Solution Approach 1:
The patent changes the voltage parameter at the input stage, converting AC to high voltage DC first, then using a DC-DC converter to step down to low voltage DC. This parameter transformation allows the use of small low voltage capacitors instead of large high voltage capacitors, as capacitor size is inversely proportional to voltage squared.
3Power
If step down transformers are used in transformer-based power supplies, then AC to DC conversion is achieved, but the transformer and associated capacitors increase in size
Solution Approach 1:
The patent extracts and removes the large step down transformer from the power conversion system. Instead, it uses a simple rectifier to convert AC to high voltage DC, then a DC-DC converter to step down the voltage, eliminating the need for bulky magnetic components.
4Volume of stationary object
If high voltage linear regulators are used, then AC to DC conversion is achieved without large transformers, but large capacitors and high power dissipation are required
Solution Approach 1:
The patent employs a DC-DC converter that operates in periodic switching cycles to step down the high voltage DC to low voltage DC. This periodic switching action enables efficient voltage conversion with minimal power dissipation, unlike continuous operation of linear regulators which dissipate excess power as heat.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient conversion with smaller components, increased input voltage range, reduced noise, and improved efficiency, enabling higher output power at lower voltages while minimizing the size and cost of the power supply module.
Implementation Method 1
a rectifier for receiving a high voltage AC line power input and for outputting a full wave, high voltage DC
Implementation Method 2
a gating component coupled to the rectifier for receiving the high voltage DC, output by the rectifier, wherein the gating component is configured to gate the high voltage DC by turning on at a zero crossing level and turning off when the high voltage DC exceeds a preset voltage threshold
Implementation Method 3
a DC-DC converter coupled to the gating component for receiving the intermediate voltage DC output by the gating component, wherein the DC-DC converter is configured to step down and smooth out the intermediate voltage DC to a desired high current, low voltage DC output
Data Source
AI summary
Methods, circuit designs, systems, and devices for the conversion of high voltage alternating current (AC) to low voltage, high current direct current (DC) are described. An exemplary apparatus includes a rectifier for receiving a high voltage AC line power input and for outputting a full wave, high voltage DC, a gating component coupled to the rectifier for receiving the high voltage DC output by the rectifier, wherein the gating component is configured to gate the high voltage DC by turning on at a zero crossing level and turning off when the high voltage DC exceeds a preset voltage threshold and wherein the output of the gating component is an intermediate voltage DC capped by the preset voltage threshold, and a DC-DC converter coupled to the gating component for receiving the intermediate voltage DC output by the gating component, wherein the DC-DC converter is configured to step down and smooth out the intermediate voltage DC to a desired high current, low voltage DC output.