Buck-Boost Contactor Drive Circuit for Wide Input Voltage Control
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Solution Overview
Problem
Conventional contactor drive circuits fail to regulate output voltage and current effectively, leading to insufficient input voltage for contactor operation and potential overvoltage issues, necessitating improved voltage regulation systems.
Innovation Solution
A voltage driver with a voltage regulation controller that operates a switching converter in multiple modes, including buck and boost modes, to ensure minimum contactor turn-on voltage is maintained, with overvoltage and undervoltage protection, and an isolation module to manage power levels, utilizing a buck-boost converter as a pass switch and employing a programmable circuit and sensor modules for control and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional pass switch is used for contactor drive, then the circuit structure is simple, but the output voltage and current cannot be regulated effectively
Solution Approach 1:
The patent implements a switching converter that dynamically changes its operation mode between buck mode and boost mode based on input voltage conditions. The controller adjusts the duty cycle of the switching elements to regulate output voltage and current, transforming the static pass switch into a dynamic voltage regulation system that adapts to varying input conditions.
2Device complexity
If the input voltage is insufficient, then the contactor drive circuit structure remains simple, but the contactor operation cannot be guaranteed
Solution Approach 1:
The patent employs a boost converter stage that changes the voltage parameter by stepping up insufficient input voltage to the required level for contactor operation. The switching converter regulates the output voltage to ensure minimum contactor turn-on voltage is achieved even when input voltage falls below the required threshold.
3Power
If high voltage is passed to the contactor, then the contactor may receive sufficient voltage for operation, but the voltage may exceed the contactor's maximum rating
Solution Approach 1:
The patent incorporates monitoring circuits that detect output voltage and current levels and provide feedback to the controller. The controller adjusts the duty cycle of the switching converter based on this feedback to maintain output voltage within safe limits, preventing overvoltage conditions that could damage the contactor.
Solution Approach 2:
The switching converter dynamically adjusts its operation between buck mode (for overvoltage protection) and boost mode (for undervoltage compensation) based on real-time voltage conditions, ensuring the output voltage remains within the contactor's rated operating range under all input conditions.
4Reliability
If a switching converter with multiple modes is implemented, then voltage regulation capability is improved, but the device complexity increases
Solution Approach 1:
The patent designs a universal switching converter that can operate in multiple modes (buck mode, boost mode, and pass-through mode) using the same basic circuit topology and control architecture. This multi-functional design allows a single device to handle both overvoltage and undervoltage conditions, reducing the need for separate voltage regulation circuits.
Data Source
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AI summary
A voltage driver includes a voltage input (180). A voltage regulation controller is operatively connected to receive input voltage from the voltage input (180) and includes an on/off input. The voltage regulation controller is configured to control a switching converter in a first mode, a second mode, at least one buck mode, and at least one boost mode. The switching converter is configured to operate as an open pass switch in the first mode, configured to operate as a closed pass switch in the second mode, configured to operate as an overcurrent and overvoltage protection switch in the at least one buck mode, and configured to operate as an undercurrent and undervoltage protection switch in the at least one boost mode.