Overvoltage Limiting via AC Voltage Converter and Rectifier

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Solution Overview

Problem

Conventional overvoltage protection devices for AC voltage generation often overheat and are limited in energy absorption, making them inefficient and unreliable in managing frequent or prolonged overvoltage states, which can damage AC voltage generating arrangements.

Innovation Solution

An overvoltage limitation device with an inverter circuit unit, rectifier, and AC voltage converter that transports power from input connections to output connections when AC voltage peak values exceed predetermined levels, allowing efficient energy management and reducing heat generation, featuring an impulse-resistant capacitor and a transformer with low leakage inductance for rapid response and high power handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional overvoltage protection devices convert overvoltage energy into heat through discharge circuits, then overvoltage can be limited, but the devices overheat and cannot handle frequent or prolonged overvoltage states

Engineering Contradiction:
Improveovervoltage protection reliabilityVSAvoiddischarge circuit temperature
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

The patent converts the harmful overvoltage energy instead of dissipating it as heat. By using an AC voltage converter (transformer) and rectifier, the overvoltage energy is transported back to the DC link, where it can be reused by the inverter circuit. This transforms the harmful overvoltage condition into recoverable energy, eliminating the overheating problem of conventional discharge circuits while maintaining reliable overvoltage protection

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent recovers the energy that would otherwise be wasted in conventional overvoltage protection. Instead of discarding overvoltage energy as heat, the system captures it through the AC voltage converter and rectifier, stores it temporarily in the DC link capacitance, and makes it available for future operation. This energy recovery approach allows handling of frequent and prolonged overvoltage states without thermal limitations

Inventive Principle:
Principle #34Discarding and recovering

2Reliability

If conventional overvoltage protection devices are used, then overvoltage can be limited, but they can only absorb limited energy and become overloaded during frequent overvoltage states

Engineering Contradiction:
Improveovervoltage protection capabilityVSAvoidenergy absorption capacity
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The system transforms the previously wasted overvoltage energy into a beneficial resource. By routing overvoltage energy through the AC voltage converter and rectifier back to the DC link, the system converts harmful excess energy into recoverable power that can support continued operation during and between overvoltage events, dramatically increasing effective energy absorption capacity

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The AC voltage converter and rectifier serve dual functions: they provide overvoltage protection while simultaneously enabling energy recovery and reuse. This multi-functionality allows the same circuit components to handle both protection and energy management tasks, effectively increasing the system's energy absorption capacity without adding separate dedicated energy storage systems

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Reliability

If overvoltage energy is converted completely into heat, then overvoltage limitation is achieved, but operational efficiency is reduced due to energy waste

Engineering Contradiction:
Improveovervoltage limitation effectivenessVSAvoidenergy conversion efficiency
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

Rather than converting overvoltage energy into wasted heat, the system converts it into useful electrical energy that can be reused. The AC voltage converter and rectifier transform the overvoltage condition into recoverable power that feeds back into the DC link, maintaining system operation and improving overall energy efficiency while providing effective overvoltage limitation

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

The solution enables reliable and efficient overvoltage limitation without overheating, allowing for longer and more frequent overvoltage management, improving the operational reliability and efficiency of AC voltage generating arrangements by minimizing energy conversion to heat and maximizing power handling capacity.

Implementation Method 1

an AC voltage converter which has a primary side and a secondary side, where the primary side is connected to the input connections and the secondary side is connected to the alternating current connection of the rectifier

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a rectifier which has an alternating current connection and a direct current connection connected to the output connections

Methodology Applied
Scientific EffectRectification: Diode

Data Source

PatentUS10348186B2Overvoltage limiting of AC voltage generation
Publication Date: 2019.07.09 TRUMPF PATENTABTEILUNG
  • US10348186B2 patent drawing
  • US10348186B2 patent drawing
  • US10348186B2 patent drawing

AI summary

An overvoltage limitation device, for an alternating current (AC) voltage generating system having an inverter circuit unit configured to supply power to a load with dynamic load impedance, includes: input connections for connection to the inverter circuit unit, output connections for connection to an intermediate circuit voltage unit connected to the inverter circuit unit, a rectifier including an alternating current connection and a direct current connection connected to the output connections, and an AC voltage converter including a primary side connected to the input connections and a secondary side connected to the alternating current connection. The overvoltage limitation device is configured such that, when peak values of an AC voltage exceed a first predetermined value at the input connections, power is transported from the input connections via the AC voltage converter and the rectifier to the output connections, and thus the AC voltage is limited to a second predetermined value.