Bidirectional Converter Burn-In Test Circuit
Solution Overview
Problem
Conventional switching power supply burn-in tests waste significant energy due to the use of high power resistors and have poor compatibility issues, requiring multiple testing equipment sets for AC/DC and DC/DC power supplies, leading to increased costs and complexity.
Innovation Solution
A simplified switching power supply burn-in test circuit utilizing an AC/DC bidirectional converter and a DC/DC load, which allows for bidirectional energy flow, reducing energy waste and improving compatibility by eliminating the need for separate circuits and manual switching, thereby testing both AC/DC and DC/DC power supplies with a single load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high power resistor is used as load for burn in test, then the power supply can be tested, but tremendous energy is wasted and converted into heat
Solution Approach 1:
The patent implements energy recovery by capturing the output energy from the power supply under test and feeding it back to the input side through AC/DC and DC/DC loads. The AC/DC load converts DC back to AC, and the DC/DC load performs DC-DC conversion, enabling the recovered energy to be reused for subsequent testing cycles, thereby significantly reducing energy waste while maintaining reliable power supply testing.
2Reliability
If separate test circuits are used for AC/DC and DC/DC power supplies, then each power supply type can be tested accurately, but the test becomes more troublesome and compatibility is poor
Solution Approach 1:
The patent designs a universal test circuit that can accommodate both AC/DC and DC/DC power supply testing through the use of bidirectional converters and configurable load modules. The AC/DC bidirectional converter can operate in both rectification and inversion modes, while the DC/DC load can be configured for different voltage levels, enabling a single circuit to perform multiple testing functions and achieve full compatibility across different power supply types.
3Reliability
If separate test circuits are used for AC/DC and DC/DC power supplies, then each power supply type can be tested, but manufacturers have to buy two different sets of testing equipments which increases cost
Solution Approach 1:
The patent merges the previously separate AC/DC and DC/DC testing circuits into a single integrated test system. By combining the AC/DC bidirectional converter, DC/DC load, and control unit into one unified platform, the system eliminates the need for manufacturers to purchase and maintain two separate sets of testing equipment, thereby reducing overall system complexity and cost while preserving comprehensive testing capability.
4Loss of energy
If AC/DC bidirectional converter and DC/DC load are used with single load configuration, then energy waste is reduced and compatibility is improved, but the circuit structure must be carefully designed
Solution Approach 1:
The patent employs dynamic switching mechanisms within the AC/DC bidirectional converter and DC/DC load to adapt the circuit configuration based on the testing requirements. The converter can dynamically switch between different operating modes (rectification, inversion, buck, boost) and the load can dynamically adjust its parameters, allowing the system to maintain energy efficiency while managing circuit complexity through intelligent control rather than fixed complex hardware.
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 solution significantly reduces energy waste and simplifies the testing process, achieving good compatibility and reducing power consumption by enabling efficient reuse of energy through bidirectional conversion, thus addressing the limitations of conventional methods.
Implementation Method 1
the AC/DC bidirectional converter rectifies the mains power into a direct current DC1
Implementation Method 2
the DC/DC switching power supply to be tested converts the direct current DC1 into a direct current DC2
Implementation Method 3
the DC/DC load converts the direct current DC2 into the direct current DC1 which is fed back to the input terminal
Implementation Method 4
the AC/DC bidirectional converter converts the direct current DC1 into an alternate current AC and outputs the alternate current AC from the AC terminal
Data Source
AI summary
A switching power supply burn in test circuit includes an AC/DC bidirectional converter, a DC/DC load and a first wire connecting end. The AC/DC bidirectional converter has an AC terminal connected to a power grid of the mains power, and a DC terminal connected to the first wire connecting end. The DC/DC load has an output terminal connected to the first wire connecting end. When the power supply to be tested is a DC/DC switching power supply, the input terminal of the DC/DC switching power supply is connected to the first wire connecting end, and its output terminal is connected to the input terminal of the DC/DC load. When the power supply to be tested is an AC/DC switching power supply, the input terminal of the AC/DC switching power supply is connected to the mains power and its output terminal is connected to the input terminal of the DC/DC load.