Modular Power Supply Communication Module Design
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Solution Overview
Problem
Conventional power supplies have fixed communication interfaces, making it inconvenient for users to change output interfaces and requiring external connectors for switching, and the communication interface cannot be replaced by users if damaged, leading to inefficient heat dissipation due to internal wire arrangements.
Innovation Solution
A power supply design featuring a casing, main board, sub-board, and communication module with a first connector that allows users to electrically connect and disconnect the communication module, enabling self-replacement and reducing internal wire usage through a socket assembly with positioning protrusions and conductive terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the communication interface is fixed in the power supply, then the structure is simple and reliable, but the user cannot replace the communication interface when damaged and must send the entire power supply for repair
Solution Approach 1:
The power supply is divided into modular components: the main board, the sub-board with the first connector, and the communication module with the second connector. This segmentation allows the communication module to be independently replaced without affecting the rest of the power supply system, resolving the contradiction between ease of repair and device complexity.
Solution Approach 2:
The communication module is extracted as a separate, replaceable component from the power supply. The sub-board with the first connector remains in the power supply, while the communication module with the second connector can be removed and replaced by the user, enabling easy repair without sending the entire power supply for maintenance.
2Temperature
If physical wires are used to connect the output interface with the power supply main board, then the electrical connection is stable, but the internal space is occupied and heat dissipation is poor
Solution Approach 1:
The physical wires are extracted from the internal connection structure and replaced by a connector-based system. The first connector on the sub-board and the second connector on the communication module provide electrical connection without requiring internal wire routing, thereby improving heat dissipation while maintaining connection stability.
Solution Approach 2:
The connectors serve as intermediaries between the power supply main board and the communication module. Instead of direct wire connections, the connectors provide a reliable electrical interface that eliminates the need for internal wire routing, improving both heat dissipation and connection reliability.
3Adaptability or versatility
If the output interface type is fixed in the power supply, then the design is simple, but the user cannot change the interface type according to their needs and must rely on external connectors
Solution Approach 1:
The power supply is designed with a universal sub-board that includes the first connector, which can interface with different types of communication modules. This allows the same power supply base to support multiple interface types (RS-232, RS-422, RS-485, CAN bus, Ethernet, LIN bus, I2C, USB) by simply changing the communication module, thereby achieving adaptability without increasing the complexity of the power supply design itself.
Data Source
AI summary
A power supply with a separable communication module includes a casing with a port; a main board placed in the casing and having a power conversion circuit; a sub-board electrically connected to the power conversion circuit and provided with at least one first connector; and a communication module. The power conversion circuit has at least one electrical connection terminal. A first interface of the first connector faces the port. The communication module includes a first circuit board and a communication circuit disposed on the first circuit board, the first circuit board has an electrical connection part electrically connected to the communication circuit, the electrical connection part has a first state of connecting with the first interface, and a second state of detaching from the first interface.