Isolated Power Acquisition Circuit for Reinforced Insulation Testing

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Solution Overview

Problem

Conventional power acquisition circuits require unplugging the voltage sampling terminal during reinforced insulation tests, leading to wasted working hours and safety hazards for production operators due to potential resistor burnout from overcurrent.

Innovation Solution

Implementing a power acquisition circuit with a high-withstand voltage DC-DC isolation transformer and switching circuit to isolate current between the acquisition and processing units, along with a communication isolation unit using an optocoupler, allowing insulation tests to be performed without unplugging the sampling terminal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If voltage sampling terminal is connected during reinforced insulation test, then production testing can proceed without unplugging, but large current may flow causing resistor burnout

Engineering Contradiction:

Improvetesting efficiencyVSAvoidovercurrent damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

An isolation transformer is introduced as an intermediary device between the voltage sampling terminal and the measurement circuit. The transformer provides galvanic isolation, allowing the sampling terminal to remain connected during reinforced insulation tests while preventing harmful currents from reaching the measurement circuit. This resolves the contradiction by enabling continuous testing (improving productivity) while the isolation transformer blocks overcurrent (preventing damage).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The power acquisition circuit is divided into isolated segments: the voltage sampling side and the measurement/processing side are separated by the isolation transformer. This segmentation allows the sampling terminal to be independently tested without affecting the measurement circuit, enabling reinforced insulation tests to proceed without unplugging while protecting sensitive components from overcurrent damage.

Inventive Principle:

Principle #1Segmentation

2Reliability

If voltage sampling terminal is unplugged during reinforced insulation test, then resistor burnout is prevented, but working hours are wasted and safety hazards increase

Engineering Contradiction:

Improveresistor protectionVSAvoidtesting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The isolation transformer serves as a protective intermediary that allows the voltage sampling terminal to remain connected during reinforced insulation tests. It provides galvanic isolation that protects the measurement circuit and resistors from overcurrent while enabling continuous testing, thus preventing resistor burnout (improving reliability) without requiring unplugging (avoiding time loss and safety hazards).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The isolation transformer is pre-installed in the circuit design, providing built-in protection before testing begins. This preliminary protective measure eliminates the need for manual unplugging operations during reinforced insulation tests, maintaining both resistor safety and testing continuity without operator intervention.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If isolation transformer is added to prevent overcurrent, then resistor burnout is prevented, but device complexity increases

Engineering Contradiction:

Improvecircuit protectionVSAvoidcircuit structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An isolation transformer is introduced as a protective intermediary device between the voltage sampling terminal and the measurement circuit. The transformer provides galvanic isolation, allowing the sampling terminal to remain connected during reinforced insulation tests while preventing harmful currents from reaching the measurement circuit. This resolves the contradiction by enabling continuous testing (improving productivity) while the isolation transformer blocks overcurrent (preventing damage).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

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

Prevents large currents during insulation tests, saving working hours and reducing safety risks by ensuring electric isolation through the power and communication isolation units, enabling safe and efficient production testing.

Implementation Method 1

converting an alternating current to a direct current and inputting the direct current to the power isolation unit

Methodology Applied

Scientific EffectElectromagnetic transformation: Electromagnetic Induction

Implementation Method 2

A first input terminal of the high-withstand voltage DC-DC isolation transformer is connected to the output terminal of the AC-DC conversion unit, a second input terminal of the high-withstand voltage DC-DC isolation transformer is connected to an output terminal of the switching circuit, and an output terminal of the high-withstand voltage DC-DC isolation transformer is connected to a power terminal of the acquisition unit, for controlling the high-withstand voltage DC-DC isolation transformer based on the control signal outputted by the switching circuit to isolate the current between the acquisition unit and the processing unit

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

The communication isolation unit is connected between a communication terminal of the acquisition unit and a communication terminal of the processing unit, for isolating a current when the acquisition unit and the processing unit are in communication

Methodology Applied

Scientific EffectOptical transmission: Photoelectric Effect

Data Source

PatentUS12480982B2Power level acquisition circuit and apparatus

Publication Date: 2025.11.25 VERTIV TECH (XIAN) CO LTD

AI summary

Provided are a power level acquisition circuit and apparatus, used for solving the problem in the prior art, when conducting reinforced insulation testing, of work hour wastage and safety hazards. A power acquisition circuit comprises an AC-DC conversion unit (20), an acquisition unit (21), a processing unit (22), a power supply isolation unit (23), and a communication isolation unit (24); the power supply isolation unit (23) isolates the current between the power supply side of the acquisition unit (21) and the power supply side of the processing unit (22), and the communication isolation unit (24) isolates the current when the communication end of the acquisition unit (21) and the communication end of the processing unit (22) are in communication; because of the presence of the power isolation unit (23) and the communication isolation unit (24), no large current occurs on the sampling unit (21) side, eliminating the need to disconnect the sampling terminal for enhanced insulation testing, saving work hours, and reducing safety hazards.