Active Rectifier Heat Sink Layout for Low-Inductance Mid-Voltage Coupling
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Solution Overview
Problem
Existing x-ray generators lack stabilized DC output voltage and power factor correction, leading to inefficiencies and increased footprint and cost due to varying decibel levels and the need for larger components.
Innovation Solution
Integrate an active rectifier with a heat sink that electrically couples AC and DC portions via a mid-voltage connection, utilizing an IGBT portion and a heat sink to reduce inductive path impedance, thereby stabilizing DC output and introducing power factor correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple diode bridge is used to convert AC to DC, then the structure is simple and cost is low, but the DC output voltage is not stabilized and power factor correction is not provided
Solution Approach 1:
The patent transforms the static diode bridge into a dynamic active rectifier system with controllable switches (IGBTs) and control circuitry. This enables real-time adjustment of switching angles and duty cycles to stabilize DC output voltage and implement power factor correction, resolving the contradiction between structural simplicity and output stability.
Solution Approach 2:
The patent changes the operating parameters of the rectifier by introducing controllable switching devices that can adjust their on/off timing and duration. This allows dynamic control of the rectification process to maintain stable DC output voltage and improve power factor, moving away from the fixed parameter operation of simple diode bridges.
2Adaptability or versatility
If larger components are used to handle varying decibel levels, then the x-ray generator can accommodate power variations, but the footprint and cost increase
Solution Approach 1:
The active rectifier provides dynamic power factor correction and voltage stabilization, allowing the system to adapt to varying power conditions without requiring oversized passive components. This dynamic control enables compact design while maintaining adaptability to power variations.
Solution Approach 2:
By actively controlling switching parameters and operating points, the system can handle varying decibel levels and power conditions without requiring larger physical components. The active control mechanisms allow compact sizing while maintaining versatility.
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
The active rectifier provides a stabilized DC output and power factor correction, enhancing efficiency and reducing the size and cost of the x-ray generator by allowing the use of smaller components.
Implementation Method 1
an insulated gate bipolar transistor (IGBT) portion positioned on top of a heat sink that electrically couples the AC portion and the DC portion
Implementation Method 2
the heat sink being positioned below the IGBT portion and between the AC portion and DC portion. In this way, a mid-voltage connection between the AC portion and the DC portion with a lower inductive path that reduces impedance of power signals may be achieved
Data Source
AI summary
Methods and systems are provided for an active rectifier comprising an alternating current (AC) portion on one side of the active rectifier, a direct current (DC) portion on another side of the active rectifier, an insulated gate bipolar transistor (IGBT) portion positioned between the AC portion and the DC portion, and a heat sink positioned below the IGBT portion and between the AC portion and DC portion, the heat sink electrically coupling the AC portion and the DC portion to achieve a reduced inductive path between the AC portion and the DC portion.