Power Converter Voltage Surge Suppression
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Solution Overview
Problem
Conventional power converters experience repeated stoppages and inefficiencies in charging due to voltage surges caused by excessive resistance and inductance in the connection between the external AC supply and the charger, leading to insufficient battery charging and reduced component lifespan.
Innovation Solution
A power converter with an input voltage detection section, a power factor correction (PFC) section, and a DC-DC conversion section, where the control section stops and resumes power conversion operations by adjusting the input current value, specifically setting a second input current value lower than the initial value after stopping, to manage voltage fluctuations and reduce voltage surges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the input current value is set according to the input voltage value in the PFC circuit, then the charger can provide desired output with different input voltage values, but when the input voltage drops excessively due to excessive resistance, the input current value switches to a different value causing voltage surge and repeated stoppages
Solution Approach 1:
The control section detects input voltage before PFC circuit operation starts and determines the appropriate input current value in advance. By setting the input current value based on pre-detected voltage conditions, the system avoids sudden current switches that cause voltage surges, thereby maintaining operational stability while adapting to different voltage levels.
Solution Approach 2:
The control section continuously monitors the input voltage and adjusts the input current value to the PFC circuit based on voltage conditions. This feedback mechanism ensures that the input current is optimized for the current voltage level, preventing voltage fluctuations and repeated stoppages while maintaining adaptability to varying input conditions.
2Reliability
If power conversion operation is stopped and resumed when input voltage exceeds assumed range, then voltage surges are avoided, but insufficient charging occurs and component life is reduced due to repeated stoppages
Solution Approach 1:
The control section detects input voltage before PFC circuit operation starts and determines the appropriate input current value in advance. By setting the input current value based on pre-detected voltage conditions, the system avoids sudden current switches that cause voltage surges, thereby maintaining operational stability while adapting to different voltage levels.
Solution Approach 2:
The system changes the input current value parameter based on detected input voltage conditions. By adjusting the input current to match the actual voltage level, the system prevents voltage surges that would cause stoppages, thereby maintaining continuous operation and improving charging efficiency without compromising protection.
3Adaptability or versatility
If the input current value is switched in the middle of charging due to voltage drop, then the PFC circuit adapts to voltage changes, but the amount of current fluctuation causes output voltage to exceed desired value and triggers stoppage
Solution Approach 1:
The control section detects input voltage before PFC circuit operation starts and determines the appropriate input current value in advance. By setting the input current value based on pre-detected voltage conditions, the system avoids sudden current switches that cause voltage surges, thereby maintaining operational stability while adapting to different voltage levels.
Solution Approach 2:
The control section continuously monitors the input voltage and adjusts the input current value to the PFC circuit based on voltage conditions. This feedback mechanism ensures that the input current is optimized for the current voltage level, preventing voltage fluctuations and repeated stoppages while maintaining adaptability to varying input conditions.
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 suppresses insufficient charging and prolongs the life of internal components by minimizing voltage surges and adjusting current values to prevent repeated stoppages and inefficiencies during charging.
Implementation Method 1
gain is adjusted by receiving input of current values respectively corresponding to the multiple input voltage values. When an input voltage value of an external AC supply is read by a control apparatus, for example, an input current value of the PFC circuit is set according to the input voltage value.
Implementation Method 2
When the amount of current fluctuation increases within a short time period, the inductance on the external AC supply side causes a voltage surge.
Implementation Method 3
when the value of resistance on the external AC supply side is excessively large, the input voltage value of the charger may drop more drastically than the assumed amount
Data Source
AI summary
A power converter includes an input voltage detection section, a power factor correction (PFC) section, a DC-DC conversion section, and a control section that stops power conversion operation in a case where an input voltage value is greater than or equal to a predetermined value. The control section resumes power conversion operation such that a second input current value lower than a first input current value corresponding to the input voltage value is input into the PFC section after stopping the power conversion operation.