Power Converter Input Protection Test Circuit
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Solution Overview
Problem
Power converters often lack effective input protection due to improper installation or disconnection of protection devices, leading to potential catastrophic failures such as excessive power losses, reactive input currents, and arcing, which can result in unsafe operation and damage.
Innovation Solution
Incorporating an input protection test function and drive fault function within the power converter that initiates a test to disconnect power and sets a flag based on the test results, ensuring the converter can only operate if it can safely disconnect from the power source, and optionally opening upstream protection devices if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If input protection devices are installed externally, then protection function is provided, but reliability is reduced due to improper installation or disconnection
Solution Approach 1:
The patent combines the input protection function with the power converter by integrating the trip signal output directly into the converter's control circuitry. This merging eliminates the need for separate external protection devices and ensures reliable operation by making the protection function an inherent part of the converter system.
Solution Approach 2:
The patent implements preliminary action by testing the input protection function during the startup sequence before the converter begins normal operation. The controller outputs a test trip signal and verifies the protection response, ensuring the protection system is functional before the converter is energized, thereby preventing catastrophic failures.
2Reliability
If protection testing is performed, then safety is improved, but operation time is increased due to test sequences
Solution Approach 1:
The protection testing is performed as a preliminary action during the startup sequence before normal operation begins. By completing the safety verification in advance, the system ensures protection functionality is confirmed while minimizing impact on operational time, as the test occurs during the necessary startup initialization phase.
Solution Approach 2:
The patent maintains continuity of useful action by integrating the protection test into the normal startup sequence rather than as a separate standalone test. This allows the testing to occur concurrently with necessary system initialization, ensuring safety verification without adding significant delays to the overall operational readiness.
3Productivity
If the converter operates without verified protection, then productivity is improved, but harmful factors increase due to potential failures
Solution Approach 1:
The controller performs a preliminary test of the input protection function by outputting a test trip signal and verifying the response before allowing normal operation. This preliminary verification ensures protection is functional, preventing catastrophic failures such as excessive power losses, reactive input currents, and arcing that could occur if protection were improperly installed or disconnected.
Solution Approach 2:
The power converter performs self-verification of its protection system by internally generating test signals and monitoring the response. This self-service capability allows the converter to autonomously confirm its protection functionality, ensuring safe operation without external intervention while preventing harmful factors through built-in verification.
Data Source
AI summary
Systems and methods in accordance with this invention provide a power converter including an input signal terminal, a first output signal at a first output signal terminal, and a controller. The controller is adapted to switch the first output signal from a first value to a second value, measure a voltage at the input signal terminal as a function of time, set a flag to a first flag value if the measured voltage falls below a predetermined value within a first predetermined time interval after the first output signal has been switched from the first value to the second value, otherwise set the flag to a second flag value, and save the flag in a memory. Numerous other aspects are also provided.