DC-DC Converter Polarity Detection and Reverse Connection Protection

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Solution Overview

Problem

Existing direct-current-to-direct-current converters face the risk of damage due to improper reverse polarity connections, which can occur over time as connectors are changed or replaced, and using distinct polarity-specific connectors increases manufacturing costs.

Innovation Solution

The implementation of a polarity protection system for direct-current-to-direct-current converters, which includes a primary and secondary direct current voltage bus, inverters, transformers, rectifiers, a removable load or energy source, a circuit breaker, a polarity detector, and a protection module with a semiconductor switch and controller, allows for detection and prevention of reverse polarity connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If distinct polarity-specific connectors are used, then reverse polarity protection is improved, but manufacturing cost increases

Engineering Contradiction:

Improvereverse polarity protectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a single universal connector design that can accommodate both correct and reverse polarity connections, eliminating the need for distinct polarity-specific connectors. This universal connector is paired with electronic polarity detection and protection circuitry that automatically detects and prevents damage from reverse polarity connections, thereby maintaining reliability while reducing manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If polarity protection circuitry is added, then device safety is improved, but device complexity increases

Engineering Contradiction:

Improvedevice safetyVSAvoidcircuit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements preliminary polarity detection before power conversion begins. The polarity detector continuously monitors the input polarity status, and the controller is pre-programmed with protection logic that automatically activates protective measures (such as blocking switching signals or activating clamping circuits) upon detecting reverse polarity, preventing damage before it occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary controller that mediates between the polarity detector and the power conversion circuitry. This controller acts as a intelligent intermediary that receives polarity detection signals and translates them into appropriate protective actions, such as modulating switching signals to the inverter bridge or activating clamping circuits, thereby simplifying the overall system architecture while maintaining comprehensive protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If connectors are changed or replaced over time, then adaptability is improved, but reverse polarity risk increases

Engineering Contradiction:

Improveconnector replaceabilityVSAvoidreverse polarity damage risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a closed-loop feedback system where the polarity detector continuously monitors the connector connection status and provides real-time feedback to the controller. This feedback mechanism enables the system to dynamically adjust its operation based on the actual polarity configuration, automatically detecting when a connector has been replaced or reconnected in reverse polarity, and activating protective measures to prevent damage.

Inventive Principle:

Principle #23Feedback

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

This solution effectively prevents damage from reverse polarity connections by automatically disconnecting the circuit when an improper connection is detected, thereby ensuring the safety and longevity of the converter and reducing manufacturing costs.

Implementation Method 1

A transformer is coupled between the primary alternating current at the primary voltage level and a secondary alternating current at the secondary voltage level

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

A secondary rectifier bridge is configured to rectify the secondary alternating current to secondary direct current of the secondary direct current bus

Methodology Applied

Scientific EffectDiode rectification: Diode

Data Source

PatentUS12316097B2Polarity protection for a converter

Publication Date: 2025.05.27 DEERE & CO

AI summary

A polarity detector is configured to detect whether a polarity of one of the secondary direct current terminals is reversed in polarity consistent with an improper connection of a removable load or the removable direct current energy source to the secondary direct current terminals. A protection module or transient clamp comprises a protection semiconductor switch with protection switched terminals and a protection control terminal. A controller is configured to control a plurality of switches of the circuit breaker and the protection module via a driver. Further, the controller is configured to open or activate the circuit breaker responsive to a signal or data message of the polarity detector detecting the improper connection.