DC Breaker Switch Regulates Link Voltage in Power Supplies
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Solution Overview
Problem
Existing power supplies face increased switching losses, noise, and standby power consumption due to high DC link voltage, which also necessitate the use of expensive high-voltage components and additional protection components.
Innovation Solution
A DC breaker switch circuit is employed to reduce and regulate the DC link voltage between the input and output stages of a power supply, using a breaker switch and control circuit to synchronize switching states with the input voltage frequency for zero voltage switching and provide inrush/surge current control and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high DC link voltage is used to drive the output stages, then the power supply can operate with standard rectifier circuitry, but switching losses, noise, and standby power consumption increase
Solution Approach 1:
The patent divides the voltage regulation function into two stages: first, standard rectifier circuitry converts AC to high voltage DC; second, a DC breaker switch circuit actively regulates the voltage down to the required level. This segmentation allows each stage to operate optimally without requiring expensive high-voltage components throughout the entire system.
Solution Approach 2:
The DC breaker switch circuit dynamically adjusts the DC link voltage based on real-time conditions by synchronizing switching operations with the AC input voltage waveform. This dynamic regulation reduces voltage to the minimum necessary level, minimizing switching losses and improving efficiency while adapting to varying load conditions.
2Power
If high DC link voltage is used, then the rectifier circuit can charge the capacitor effectively, but expensive high voltage components are required
Solution Approach 1:
The system segments the voltage handling requirements: the rectifier stage handles high voltage briefly during AC peaks, while the DC breaker switch circuit maintains lower regulated voltage during steady-state operation. This allows most components to be rated for lower voltages, reducing cost while maintaining rectifier effectiveness.
Solution Approach 2:
The patent changes the voltage parameter dynamically - allowing high voltage during rectification peaks when necessary, then actively regulating down to lower operating voltage. This parameter modulation enables the use of lower-voltage-rated, less expensive components for the majority of operating conditions.
3Power
If high DC link voltage is used, then the capacitor can be charged to sufficient levels, but inrush and surge current control becomes more difficult
Solution Approach 1:
The DC breaker switch circuit performs preliminary voltage regulation before power reaches the output stages, preventing inrush and surge currents from developing. By controlling the charging process from the beginning through synchronized switching, the system avoids the need for additional protection components like fuses and thermistors.
Solution Approach 2:
The system uses feedback control through the DC breaker switch circuit to monitor and regulate DC link voltage in real-time. This feedback mechanism naturally limits inrush and surge currents by adjusting switching timing and duty cycle, eliminating the need for separate protection circuitry while ensuring safe capacitor charging.
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 reduces power consumption during standby operation, allows for the use of lower voltage rated components, and eliminates the need for costly protection components, resulting in increased efficiency and lower costs.
Implementation Method 1
synchronize switching states with the input voltage frequency for zero voltage switching
Implementation Method 2
A DC breaker switch circuit is employed to reduce and regulate the DC link voltage
Implementation Method 3
provide inrush/surge current control and protection
Data Source
AI summary
Generally, this disclosure provides circuits and methods to reduce and regulate DC link voltage in a power supply through the use of a DC breaker circuit. The breaker circuit may include a breaker switch configured to couple an input stage circuit of a power supply to an output stage circuit of the power supply and to provide a regulated DC link voltage to the output stage circuit, the level of the DC link voltage based on switching states of the breaker switch. The breaker circuit may further include a control circuit configured to generate a gate control signal to control the switching states of the breaker switch, the gate control signal based on a comparison of the DC link voltage to a high voltage threshold and a low voltage threshold, such that the magnitude of the DC link voltage is regulated to a set point and a peak-to-peak ripple.