Integrated UPS Circuit Board Design for Cost and Harmonic Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional UPS products have complex circuit designs with extra circuit boards for noise filtering, surge protection, and high voltage circuit breakers, leading to increased production costs, reduced reliability, and inefficiencies such as high total harmonic distortion and reduced battery life.
Innovation Solution
An integrated UPS design that combines a UPS main board with a controller and battery pack, incorporating a noise filtering surge protecting high voltage circuit breaker, high power factor correction rectifier, inverter, high power charger, and DC/DC converter on a single circuit board, eliminating the need for an extra high power factor correction circuit and reducing circuit size and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extra circuit boards for noise filter, surge protector and high voltage circuit breaker are added to conventional UPS products, then the UPS provides comprehensive protection functions, but the device complexity and production cost increase
Solution Approach 1:
The patent integrates the noise filter, surge protector, high voltage circuit breaker, and high power factor correction circuit into a single circuit board. The circuit board includes an AC input terminal coupled to a noise filter, which is coupled to a surge protector, coupled to a high voltage circuit breaker, coupled to a high power factor correction circuit. This merging eliminates the need for separate circuit boards for each protection function, reducing device complexity while maintaining comprehensive protection capabilities.
Solution Approach 2:
The single circuit board performs multiple functions simultaneously: noise filtering, surge protection, high voltage circuit breaking, and high power factor correction. The AC input terminal connects to components that collectively provide all these protection and correction functions in one integrated unit, making the circuit board universal in its capabilities rather than requiring specialized separate boards for each function.
2Reliability
If multiple separate circuit boards are used for noise filtering, surge protection and high voltage circuit breaking, then each component can be optimized independently, but the production cost and difficulty of circuit control increase
Solution Approach 1:
The patent combines multiple protection circuits into one circuit board design. The circuit board includes an AC input terminal coupled to a noise filter, which is coupled to a surge protector, coupled to a high voltage circuit breaker, coupled to a high power factor correction circuit. This integration reduces the number of separate components that need to be manufactured and assembled, lowering production costs and simplifying circuit control while maintaining the ability to optimize each function within the integrated design.
3Ease of operation
If conventional UPS design with separate circuit boards is used, then installation and maintenance are straightforward, but the charging efficiency and battery life are reduced
Solution Approach 1:
The patent integrates the high power factor correction circuit with the charger circuit on the same circuit board. The high power factor correction circuit is coupled to a rectifier that outputs DC to a DC bus, which connects to the charger circuit. This integration improves charging efficiency by reducing power losses and harmonics, while the unified circuit board design maintains ease of installation and maintenance compared to multiple separate boards.
Solution Approach 2:
The high power factor correction circuit changes the electrical parameters of the input power by correcting the power factor and reducing total harmonic distortion. This parameter optimization improves the quality of power delivered to the battery, increasing charging efficiency and extending battery life while maintaining compatibility with standard installation procedures.
4Reliability
If extra circuit boards are added to provide comprehensive protection, then the UPS reliability improves, but the material costs and production complexity increase
Solution Approach 1:
The patent consolidates multiple protection functions into a single circuit board, reducing the total quantity of materials required. The circuit board includes an AC input terminal coupled to a noise filter, which is coupled to a surge protector, coupled to a high voltage circuit breaker, coupled to a high power factor correction circuit. By merging these functions, the patent reduces material costs while maintaining comprehensive protection coverage.
Solution Approach 2:
The integrated circuit board provides multiple protection functions simultaneously, making each component on the board more versatile. This multi-functionality reduces the overall material requirements compared to having separate dedicated circuit boards for each protection function, thereby reducing material costs while maintaining full protection capabilities.
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 integration reduces total harmonic distortion, input current ripples, and crosstalk, increases the input power factor and charging efficiency, and extends battery life while lowering production costs and improving reliability.
Implementation Method 1
a high power factor correction rectifier, coupled with the noise filtering surge protecting high voltage circuit breaker and outputs a DC
Implementation Method 2
the high power charger has rectification and high power factor correction functions
Implementation Method 3
an inverter, coupled with the DC bus
Implementation Method 4
the high power charger charges the battery pack using the DC from the high power factor correction rectifier
Implementation Method 5
a noise filtering surge protecting high voltage circuit breaker
Implementation Method 6
a noise filtering surge protecting high voltage circuit breaker
Implementation Method 7
a DC/DC convertor, coupled with the first battery contact and the second battery contact, and is coupled with the DC bus
Data Source
AI summary
An integrated uninterruptible power supply (UPS) includes a UPS main board coupled with a controller and a battery pack. The UPS main board includes an AC (alternating current) input, a noise filtering surge protecting high voltage circuit breaker, a high power factor correction rectifier, a DC (direct current) bus, an inverter, a high power charger, a first battery contact, a second battery contact, a DC/DC convertor and an AC output. The present disclosure integrates a noise filter, a surge protector and a high voltage circuit breaker, and integrates a high power charger in the same circuit board. Therefore, the present disclosure lowers the material and production costs of UPS products, and decreases the circuit board size. In addition, the present disclosure decreases the total harmonic distortion, the ripples of input current, and the crosstalk between circuits, and increases the input power factor, the charging efficiency and the battery life.