Bidirectional Bridge Rectifier Surge Protection Circuit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing digital input modules struggle with effective surge protection against electrical transients, particularly in high-density compact multi-channel designs, due to limitations in board temperature, size, and cost, as governed by standards like IEC 61000-4-2, IEC 61000-4-4, and IEC 61000-4-5.
Innovation Solution
A bidirectional bridge rectifier circuit with integrated transient voltage suppression (TVS) diodes provides surge protection by acting as an input stage protector for digital input circuits, offering a more compact and cost-effective solution by using fewer components, with rectification legs including TVS diodes for transient suppression and rectifier diodes for signal conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional surge protection circuits are used for digital input modules, then surge protection capability is provided, but board size, component count, and cost increase
Solution Approach 1:
The patent combines multiple surge protection functions into a single integrated bridge rectifier component. The bridge rectifier integrates TVS diodes for transient suppression, rectifier diodes for signal conversion, and ESD protection capabilities into one unified component, replacing what would traditionally require multiple separate components. This merging reduces component count while maintaining comprehensive surge protection capability across ESD, EFT, and surge immunity standards.
Solution Approach 2:
The bridge rectifier component performs multiple functions simultaneously: it provides surge protection, ESD protection, signal rectification, and transient voltage suppression. This multi-functional approach eliminates the need for separate protection circuits and signal conditioning components, thereby reducing overall device complexity and component count while maintaining reliable surge protection capability.
2Reliability
If multiple separate protection components are used, then comprehensive surge protection is achieved, but board area and temperature management become problematic
Solution Approach 1:
By integrating multiple protection functions into a single bridge rectifier component, the patent significantly reduces the board area required for surge protection. Instead of placing multiple separate components (TVS diodes, rectifier diodes, protection circuits) that each require their own mounting space, the integrated solution consolidates all these functions into one compact component footprint.
3Reliability
If traditional protection circuits are implemented, then surge protection is provided, but manufacturing cost increases
Solution Approach 1:
The integration of multiple protection functions into a single bridge rectifier component reduces manufacturing cost by eliminating the need to source, stock, and assemble multiple separate components. The single-component approach simplifies the supply chain, reduces assembly steps, and lowers overall bill of materials cost while maintaining compliance with IEC 61000-4-2, IEC 61000-4-4, and IEC 61000-4-5 standards.
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 effectively suppresses surges, maintaining safe voltage levels during high voltage/current events, reducing component count and costs, while ensuring compliance with electrical transient protection standards, as illustrated by the ability to withstand 25A for 20us with input voltage below maximum specified limits.
Implementation Method 1
rectification legs D1 and D4 including transient circuit suppression (TVS) diodes
Implementation Method 2
rectification legs D2 and D3 including rectifier diodes
Data Source
AI summary
A circuit for providing input surge protection in a digital input module, the circuit comprising a surge protection input stage, including a bridge rectifier coupled to receive the bidirectional input signal, and coupled to the unidirectional input of the digital input module. The bridge rectifier comprises TVS rectifiers TVS1 and TVS2, and diode rectifiers D2 and D3, intercoupled in a bridge rectifier configuration in which: TVS1 and TVS4 are transient voltage suppression diodes; and rectifiers D2 and D3 are rectifier diodes. Diodes TVS1 and TVS4 can be implemented as either respective unidirectional TVS diodes; or a single bidirectional TVS diode. The digital input module can be a digital input receiver, or a opto-isolator/coupler, or other digital input module.