Adaptive Power Controller Switching Circuit

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Solution Overview

Problem

Conventional power controllers face inefficiencies and increased costs due to fixed pre-charging time periods and the need for larger, more costly inrush current limiting circuits, as well as limited lifespan transient voltage surge suppressors, which can lead to damage from inrush currents and kickback voltages, and a lack of load health monitoring capabilities.

Innovation Solution

A power controller with a switching circuit that includes a first and second path, where the second path is activated for a time period based on the state-of-charge of the load, and a processing unit that dynamically controls the switches to optimize pre-charging and reduce kickback voltage, while also monitoring load health and capacitance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fixed predetermined time period is used for pre-charging the load through the second path, then the inrush current is limited, but the time to primary conduction is increased and the circuit components must be sized for repeated full-duration activation

Engineering Contradiction:

Improveinrush current protectionVSAvoidtime to primary conduction

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements dynamic control of the pre-charging time period based on real-time monitoring of the load's state-of-charge. The processing unit adjusts the duration the second path remains active according to actual load conditions rather than using a fixed predetermined time, thereby optimizing the balance between inrush current protection and minimizing time to primary conduction.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The circuit sensor provides feedback signals indicating the state-of-charge of the load to the processing unit. This feedback mechanism enables the system to monitor load conditions and dynamically adjust the pre-charging duration, allowing the second path to be deactivated earlier when the load is sufficiently charged, thus reducing the time to primary conduction while maintaining reliable inrush current protection.

Inventive Principle:

Principle #23Feedback

2Reliability

If the second path is configured to withstand repeated cycles of activation for the entire time period, then inrush current is limited, but the second path must be larger and more costly

Engineering Contradiction:

Improveinrush current protectionVSAvoidsecond path configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Inventive Principle:

Principle #23Feedback

3Reliability

If the second path is frequently activated for the entire predetermined time period, then inrush current is limited, but the second path experiences higher temperatures that may damage the power controller

Engineering Contradiction:

Improveinrush current protectionVSAvoidsecond path temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the operational parameters of the second path by dynamically adjusting the pre-charging time period based on load conditions. This parameter change reduces the duration of current flow through the second path during frequent activations, thereby reducing heat generation and temperature buildup while maintaining effective inrush current protection.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If TVSS is used to absorb kickback voltage, then switch protection is provided, but the TVSS has limited lifetimes based on the number and magnitude of voltage kickbacks

Engineering Contradiction:

Improveswitch protectionVSAvoidTVSS lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies preliminary action by implementing a soft-turn-off sequence where the second path is activated before the first path is deactivated. This preliminary action of gradually reducing current through the first path before complete switch-off minimizes the magnitude of kickback voltage generated, thereby protecting the TVSS and extending its operational lifespan while maintaining switch protection.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3345273B1Power controller having adaptive control of a switching circuit

Publication Date: 2022.05.18 TE CONNECTIVITY CORP

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AI summary

Power controller (100) includes a switching circuit (106) that is configured to provide electrical power to a load (102). The switching circuit (106) includes a first path (108) having a first switch (112) and a second path (110) that is in parallel with the first path (108) prior to the load (102). The second path (110) includes a second switch (114). The switching circuit (106) is in a soft-switching state when the second path (110) is activated and the first path (108) is deactivated. The switching circuit (106) is in an operational state when the second path (110) is deactivated and the first path (108) is activated. The power controller (100) includes a processing unit (120) that is configured to open or close the first and second switches (112), (114) to change the switching circuit (106) between the soft-switching state and the operational state.