Auxiliary DC Bus Power Conversion for Peak-Limited AC Inputs

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Solution Overview

Problem

Standard electrical wiring systems are inadequate for non-standard devices requiring higher peak power demands, necessitating costly and time-consuming redesign or replacement to support higher peak current and voltage levels.

Innovation Solution

A power converter system that includes an auxiliary power source to supplement input power, a charger to convert AC power to DC power, and power converters to manage voltage and current levels, allowing the system to provide output power exceeding the peak limits of the input power source.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the electrical wiring system is redesigned or replaced to support higher peak power demand, then the power capacity is improved, but the implementation time and cost increase

Engineering Contradiction:
Improvepeak power capacityVSAvoidimplementation time
Core Design Contradiction:
PowerVSLoss of time

Solution Approach 1:

The system performs preliminary action by charging the auxiliary power source during periods of low power demand. The charger converts input AC power to DC power and stores it in the auxiliary power source (battery) when the load demand is below the peak voltage limit, so that power is already available when high peak power demand occurs, eliminating the need for immediate wiring redesign

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The auxiliary power source acts as an intermediary between the input power source and the load. It mediates power delivery by supplementing the charger's output during peak demand periods, enabling the system to deliver peak power exceeding the input power source's voltage limit without requiring changes to the input wiring infrastructure

Inventive Principle:
Principle #24Intermediary (Mediator)

2Power

If the electrical wiring system is redesigned or replaced to support higher peak power demand, then the power capacity is improved, but the implementation cost increases

Engineering Contradiction:
Improvepeak power capacityVSAvoidimplementation cost
Core Design Contradiction:
PowerVSEase of manufacture

Solution Approach 1:

The system performs preliminary action by charging the auxiliary power source during periods of low power demand. The charger converts input AC power to DC power and stores it in the auxiliary power source (battery) when the load demand is below the peak voltage limit, so that power is already available when high peak power demand occurs, eliminating the need for immediate wiring redesign

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The auxiliary power source acts as an intermediary between the input power source and the load. It mediates power delivery by supplementing the charger's output during peak demand periods, enabling the system to deliver peak power exceeding the input power source's voltage limit without requiring changes to the input wiring infrastructure

Inventive Principle:
Principle #24Intermediary (Mediator)

3Adaptability or versatility

If standard electrical wiring systems are used, then the system complexity is reduced, but the adaptability to non-standard devices decreases

Engineering Contradiction:
Improvecompatibility with non-standard devicesVSAvoidsystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The power converter system achieves universality by being capable of serving both standard devices (within peak voltage limit) and non-standard devices (exceeding peak voltage limit). The controller dynamically manages power flow from the charger and auxiliary power source to accommodate varying load requirements, making the system adaptable to different device types without requiring separate wiring infrastructures

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system implements dynamics through the controller's real-time monitoring and adjustment of power flow. The controller dynamically switches between charging the auxiliary power source and drawing from it based on whether the load demand exceeds the peak voltage limit, enabling flexible adaptation to changing operational conditions and device requirements

Inventive Principle:
Principle #15Dynamics

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

Enables efficient and cost-effective support for non-standard devices with higher peak power demands by dynamically adjusting power levels, reducing the need for extensive system redesign and replacement.

Implementation Method 1

a charger coupled to the input and configured to convert the input AC power into first DC power having a first voltage level

Methodology Applied
Scientific EffectAC to DC conversion:

Implementation Method 2

at least one power converter coupled to the DC bus and configured to convert DC power from the DC bus into the output power

Methodology Applied
Scientific EffectDC to AC conversion:

Implementation Method 3

a voltage level of the AC output power is greater than the peak voltage limit of the input power source

Methodology Applied
Scientific EffectVoltage transformation:

Implementation Method 4

an auxiliary power source coupled to the DC bus and configured to provide second DC power having the first voltage level to the DC bus to supplement the first DC power provided by the charger in response to a voltage demand of the at least one load exceeding the peak voltage limit

Methodology Applied
Scientific EffectPower supplementation:

Data Source

PatentUS11749993B2Method to overcome electrical circuit voltage and current limitations
Publication Date: 2023.09.05 SCHNEIDER ELECTRIC IT CORP
  • US11749993B2 patent drawing
  • US11749993B2 patent drawing
  • US11749993B2 patent drawing

AI summary

A power converter system including an input configured to receive input AC power from an input power source, the input power source having a peak voltage limit, at least one output configured to provide output power to at least one load, a charger coupled to the input and configured to convert the input AC power into first DC power, a DC bus configured to receive the first DC power, at least one power converter configured to convert DC power from the DC bus into the output power, and an auxiliary power source coupled to the DC bus and configured to provide second DC power to the DC bus to supplement the first DC power provided by the charger in response to a voltage demand of the at least one load exceeding the peak voltage limit of the input power source.