Fault-Tolerant Full-Bridge Rectifier Using Dual MOSFET Isolation
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Solution Overview
Problem
Contemporary electronic systems require fault-tolerant power supplies that can maintain operation even in the event of one or more power converter failures, but existing fault-tolerant power systems face challenges in efficiently managing power distribution and minimizing losses, especially at high currents and low voltages.
Innovation Solution
The implementation of a fault-tolerant power converter system using a transformer with series circuits and dual MOSFET semiconductor devices, where switches are controlled to prevent short circuits and ensure continued operation even if one switch fails, utilizing a full-bridge rectification circuit and common-source dual MOSFET devices to manage power flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional disconnect switches are added to isolate failed converters, then system reliability is improved, but device complexity and power losses increase
Solution Approach 1:
The patent combines the fault isolation function with the existing output switching devices. The second switch in each parallel circuit serves dual purposes: normal power switching and fault isolation. When a fault is detected, the control circuit opens the second switch to isolate the failed converter, eliminating the need for separate disconnect switches at the output.
Solution Approach 2:
The second switch is designed to perform multiple functions: it acts as a normal switching element during healthy operation and simultaneously serves as a fault isolation mechanism when failures occur. This multi-functionality reduces the total component count while maintaining reliability.
2Reliability
If additional disconnect switches are added to isolate failed converters, then system reliability is improved, but power losses increase
Solution Approach 1:
The patent merges the fault isolation function with existing output switches, eliminating the need for additional disconnect switches. This reduces the total number of switching components in the current path, thereby minimizing cumulative power losses while maintaining the ability to isolate failures.
3Productivity
If converters are connected in parallel to share power, then productivity is improved, but the risk of short circuits affecting the entire system increases
Solution Approach 1:
The control circuit continuously monitors the operation of each converter and prepares isolation switches in advance. When a short circuit fault is detected in any converter, the control circuit immediately opens the corresponding second switch to isolate the faulty unit, preventing the short circuit from propagating to other parallel converters and the main bus.
Solution Approach 2:
The second switch acts as an intermediary element between each converter and the main power bus. It provides a controlled isolation point that can quickly disconnect faulty converters, preventing harmful short circuits from affecting the entire parallel system while allowing healthy converters to continue operating.
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 enables efficient fault-tolerant power distribution, reducing power losses and maintaining system operation even if one switch fails, by ensuring that no switch turns on if its complementary switch is not functioning correctly, thus preventing short circuits and allowing the system to continue powering loads without additional isolation switches.
Implementation Method 1
a transformer having a primary winding and a secondary winding
Implementation Method 2
a first switch and a second switch each adapted to block current flow in an OFF state
Data Source
AI summary
A power converter provides a low-voltage output using a full-bridge fault-tolerant rectification circuit. The output circuit uses controlled switches as rectifiers. A fault detection circuit monitors circuit conditions. Upon detection of a fault, the switches are disabled decoupling the power converter from the system.A common-source dual MOSFET device includes a plurality of elements arranged in alternating patterns on a semiconductor die. A common-source dual synchronous rectifier includes control circuitry powered from the drain to source voltage of the complementary switch.A DC-to-DC transformer converts power from an input source to a load using a fixed voltage transformation ratio. A clamp phase may be used to reduce power losses in the converter at light loads, control the effective output resistance of the converter, effectively regulate the voltage transformation ratio, provide narrow band output regulation, and control the rate of change of output voltage for example during start up. One or more of the transformer windings may be clamped. The converter may use the sine amplitude converter topology. The converter may use common-source dual MOSFET devices and fault detection.The density of point of load power conversion may be increased and the associated power dissipation reduced by removing the input driver circuitry from the point of load where it is not necessary. An output circuit may be located at the point of load providing fault tolerant rectification of the AC power from the secondary winding of a power transformer which may be located nearby the output circuit. The resonant voltage and current waveforms on the primary side of the transformer are readily communicated via an AC bus between the driver circuit and the primary winding of the power transformer. The driver circuit may drive a plurality of transformer-output circuit pairs. The transformer and output circuit may be combined in a single module at the point of load. Alternatively, the output circuit may be integrated into point of load circuitry such as a processor core. The transformer may be deployed near the output circuit.