Intermediate Circuit Coupling for Flexible Multichannel Test Power

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing multichannel test systems face limitations in power capacity and flexibility due to galvanic separation, which restricts power supply to individual channels and requires complex solutions for coupling intermediate circuits, leading to high equalizing currents and lengthy switching processes.

Innovation Solution

A multichannel test system with switchable coupling and separation of galvanically separated test channels, utilizing controllable power converter circuits with active and passive operating modes, and a switching device to form or separate intermediate circuits, allowing flexible power distribution and rapid configuration changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If intermediate circuits are galvanically separated in multichannel test systems, then supply stability and measurement precision are improved, but power capacity and flexibility are limited

Engineering Contradiction:

Improveinsulation resistance measurementVSAvoidpower capacity

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The system dynamically switches between galvanic separation mode (for measurement precision) and galvanic coupling mode (for power capacity). The intermediate circuits can be coupled or separated based on operational requirements, making the system adaptable to different test scenarios.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system is divided into multiple independently controllable channels with separate intermediate circuits. Each channel can operate independently when separation is needed, or be combined when increased power capacity is required, providing flexibility through modular architecture.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If intermediate circuits are galvanically coupled to increase power capacity, then power flexibility is improved, but equalizing currents and switching complexity increase

Engineering Contradiction:

Improvepower capacityVSAvoidswitching process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Before coupling intermediate circuits, the system performs preliminary voltage equalization by adjusting the output voltages of individual power converter circuits. This preliminary action prevents harmful equalizing currents during the coupling process and simplifies the switching operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback control through controllable power converter circuits to monitor and adjust intermediate circuit voltages before and during coupling. This feedback mechanism ensures safe switching by preventing excessive equalizing currents and managing the coupling process automatically.

Inventive Principle:

Principle #23Feedback

3Productivity

If switching between coupled and separated intermediate circuits is performed rapidly, then system flexibility is improved, but switching time and equalizing currents increase

Engineering Contradiction:

Improveconfiguration switching speedVSAvoidswitching time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary voltage adjustment and equalization before the actual switching operation. By preparing the intermediate circuits in advance (adjusting voltages to match), the actual coupling or separation can be executed rapidly without prolonged switching transients or harmful currents.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual or mechanical switching with electronically controlled power converter circuits that can adjust voltages and perform coupling/separation rapidly. This electronic control substitutes slower mechanical switching mechanisms, reducing switching time and improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables flexible power capacity increase and rapid switching between single-channel and multichannel configurations, minimizing equalizing currents and reducing switching times to seconds, while maintaining isolation and power stability.

Implementation Method 1

Each of the test channels comprises a controllable power converter circuit which is used to convert electrical power between the supply grid and the DC-carrying intermediate circuit of the test channel in a controlled manner

Methodology Applied

Scientific EffectElectromagnetic transformation: Electromagnetic Induction

Data Source

PatentUS12592561B2Multichannel test system with galvanic coupling of intermediate circuits, and method for galvanically coupling intermediate circuits

Publication Date: 2026.03.31 AVL LIST GMBH

AI summary

The present invention relates to a multichannel test system (100) and to a method for supplying test load devices (61, 62) with electrical power from a supply grid, comprising at least a first test channel (10) and a second test channel (20) which are galvanically separated. At least one switching device (40) is provided for galvanically coupling intermediate circuits (13, 23) of the test channels (10, 20) in a switchable manner to form a common intermediate circuit. For this purpose, in addition to phase-controlled, variably adjustable rectification, uncontrolled, invariable rectification is also provided in a passive operating mode by an active power stage (12, 22) in power converter circuits (16, 26, 36) of the test channels (10, 20, 30).