Modular DC Power Supply Dynamic Intermediate Voltage Control
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Solution Overview
Problem
Conventional two-stage power supplies with electronic fuses for overload protection are complex, require significant space and cabling, and suffer from power losses and limited operational time during overload conditions.
Innovation Solution
A power supply design where the intermediate circuit voltage is dynamically controlled by a DC-DC converter and output switching regulators, allowing regulation of the output voltage without fixed intermediate circuit voltage, with current limiting and switch-off mechanisms to prevent component damage, using extra-low voltage components and resonant converters for efficiency, and multiple output switching regulators for parallel load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic fuses are used for overload protection in conventional two-stage power supplies, then output voltage safeguarding is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines the overload protection function with the existing output switching regulator by integrating a current regulator stage. This merges the safeguarding function into the power conversion path rather than adding separate protective devices, thereby reducing device complexity while maintaining reliability.
Solution Approach 2:
The output switching regulator is designed to perform multiple functions: voltage regulation and overload protection. By making the regulator universal, the system eliminates the need for separate electronic fuses, reducing both device complexity and space requirements while maintaining output voltage safeguarding.
2Reliability
If electronic fuses are used for overload protection, then output voltage safeguarding is achieved, but space and cabling requirements increase
Solution Approach 1:
The protection function is merged into the compact switching regulator circuitry, eliminating the need for separate fuse components and their associated mounting space, connection terminals, and cabling infrastructure.
Solution Approach 2:
The separate electronic fuse component is extracted from the system and its protection function is implemented through the existing switching regulator, eliminating the physical space and cabling requirements associated with discrete fuse components.
3Reliability
If conventional power supplies with electronic fuses are used, then overload protection is achieved, but power losses increase
Solution Approach 1:
The current regulator continuously monitors the output current and provides feedback control to limit current to the maximum allowable value. This active feedback mechanism replaces passive fuse operation, reducing power losses by maintaining optimal current levels rather than allowing excessive current flow.
Solution Approach 2:
The system transitions from static fuse-based protection to dynamic current regulation, where the current limit is actively controlled and adjusted based on real-time conditions, optimizing power efficiency while maintaining protection.
4Reliability
If electronic fuses are used for overload protection, then safeguarding is achieved, but operational time during overload is limited
Solution Approach 1:
The current regulator preemptively limits the output current to the maximum allowable value before overload damage can occur. By acting in advance to prevent excessive current, the system extends operational time during overload conditions while still protecting components.
Solution Approach 2:
The dynamic current regulation allows the system to adapt to overload conditions by maintaining controlled current levels, extending the duration of safe operation compared to static fuse-based systems that must immediately disconnect.
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 design reduces device complexity, saves space and cabling, prevents component damage during overloads, and maintains continuous operation with reduced conduction losses and costs, while allowing flexible load management and efficient power transfer.
Implementation Method 1
An input-side supply voltage is regulated to a largely constant intermediate circuit voltage in this connection. This occurs with a step-down switching regulator and/or a step-up switching regulator.
Implementation Method 2
This occurs with a step-down switching regulator and/or a step-up switching regulator.
Implementation Method 3
using extra-low voltage components and resonant converters for efficiency
Data Source
AI summary
A power supply with a DC-DC converter and a switching converter comprises an intermediate circuit and at least one output switching regulator. The intermediate circuit has an intermediate circuit voltage, and is connected to a supply voltage via the DC-DC converter. The at least one output switching regulator is connected to the intermediate circuit, and configured to supply, on the output side, a regulated output voltage.