Multi-Input Power Conversion with Shared PFC and DC-DC Stages
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Solution Overview
Problem
Existing dual-input switching power converters require two PFC converters and two DC-to-DC converters, leading to high circuit cost and complexity.
Innovation Solution
A multi-input power system with a switching switch, boost power factor correction circuit, DC-to-DC conversion circuit, determination circuit, and switch control circuit, allowing for the selection of one input power source as the main and another as backup, using only one boost PFC and one DC-to-DC conversion circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two PFC converters and two DC-to-DC converters are used for dual-input power conversion, then the system can process multiple AC power sources independently, but the circuit cost and device complexity increase significantly
Solution Approach 1:
The patent merges two independent power conversion paths into a single integrated converter that can handle multiple AC inputs. The single converter incorporates multiple rectification circuits for different AC sources, a unified PFC stage, and a single DC-to-DC conversion stage, eliminating the need for separate converters for each input source while maintaining the ability to process multiple power sources independently
Solution Approach 2:
The single power converter is designed with universal functionality to accept multiple AC power sources (e.g., utility AC, generator AC, battery DC via rectifier) as inputs. The converter's control system automatically detects the input source type and adjusts operating parameters accordingly, allowing one device to perform the functions previously requiring multiple dedicated converters
2Reliability
If two independent power conversion paths are used, then each input power source can be processed with dedicated PFC and DC-to-DC converters, but the overall system volume and component cost increase
Solution Approach 1:
The patent combines multiple power conversion functions into a single integrated converter unit. The converter includes a common magnetic component (transformer or inductor) that serves both the PFC function and the DC-to-DC conversion function, eliminating the need for separate magnetic components for each conversion stage. This merging reduces the overall system volume while maintaining reliable power conversion for multiple input sources
3Manufacturing precision
If multiple PFC and DC-to-DC converters are implemented, then comprehensive power factor correction and voltage conversion can be achieved for each input, but the control complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the PFC control and DC-to-DC conversion control into a single integrated control system. The controller monitors the input power source characteristics and automatically adjusts the switching duty cycles for both the PFC stage and the DC-to-DC stage to maintain optimal power factor correction and voltage conversion accuracy. This unified control approach simplifies manufacturing by reducing the number of control circuits and sensors required
Solution Approach 2:
The control system dynamically changes operating parameters (switching frequency, duty cycle, phase angle) based on the detected input power source type and load conditions. By adjusting these parameters in real-time, the single converter achieves the same level of power factor correction precision and voltage conversion accuracy as multiple dedicated converters would provide, while simplifying the overall control architecture
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
Simplifies the power supply structure, reduces component cost and volume, and achieves higher conversion efficiency by selecting the input power source with a higher voltage.
Implementation Method 1
The at least two filter-rectification circuits respectively receive the at least two input power sources, and convert the at least two input power sources into at least two rectified voltages
Implementation Method 2
The boost power factor correction circuit receives the rectified voltage provided from the switching switch, and performs a power factor correction to the rectified voltage to provide a conversion voltage
Implementation Method 3
The DC-to-DC conversion circuit is connected to the boost power factor correction circuit and the DC-to-DC conversion circuit converts the conversion voltage into an output voltage
Data Source
AI summary
A multi-input power system receives at least two input power sources, and includes at least two filter-rectification circuits, a switching switch, a boost power factor correction circuit, a DC-to-DC conversion circuit, a determination circuit, and a switch control circuit. The at least two filter-rectification circuits correspondingly convert the at least two input power sources into at least two rectified voltages. The switching switch switches one of the at least two rectified voltages. The determination circuit receives at least two power information, and determines at least two power supply status of the at least two input power sources according to the at least two power information to generate a determination signal. The switch control circuit receives the determination signal to generate a switch control signal to control the switching switch so as to switch one of the at least two rectification voltages.