PFC AC/DC Converter Calibration for Safe Output Voltage Control
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Solution Overview
Problem
AC/DC converters with power factor correction in electric vehicle chargers face challenges in accurately regulating output voltage within safe limits, leading to potential instability and component damage due to manufacturing uncertainties and cost constraints, especially in mass production environments where safety regulations restrict live part access for adjustments.
Innovation Solution
A method for calibrating AC/DC converters by connecting the input connector to a predetermined DC voltage power supply, measuring and calibrating the voltage measuring means to ensure accurate DC voltage delivery within safe voltage thresholds, allowing the use of standard, inexpensive components and compliance with safety regulations in industrial production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-end accurate components are chosen for voltage measuring means and servo-control device, then output voltage regulation accuracy is improved, but cost increases significantly
Solution Approach 1:
The patent applies preliminary action by performing voltage calibration during the manufacturing process before the product is delivered to the customer. A calibration device measures the actual output voltage and adjusts the servo-control reference voltage to compensate for component tolerances, thereby achieving accurate voltage regulation without requiring expensive high-precision components.
Solution Approach 2:
The system performs self-calibration using its own internal resources. The calibration device utilizes the converter's existing voltage measuring means and servo-control device to automatically adjust and compensate for inaccuracies, eliminating the need for external high-precision calibration equipment or manual adjustment by skilled technicians.
2Reliability
If components with higher voltage withstand (e.g., 1000 volts) are chosen, then the risk of exceeding maximum voltage thresholds is reduced, but the components become larger, more expensive and less accurate
Solution Approach 1:
The patent changes the operating parameters of the standard components by dynamically adjusting the reference voltage of the servo-control device based on actual measurements. This allows standard 400-volt components to operate reliably within their specifications while maintaining accurate output voltage regulation, avoiding the need for oversized 1000-volt components.
3Measurement precision
If adjustments during manufacture are performed using external diagnostic means, then voltage regulation accuracy can be improved, but safety regulations prohibiting access to live electrical parts are violated
Solution Approach 1:
The patent introduces a calibration device as an intermediary that interfaces with the converter through protected terminals. This device enables accurate voltage measurement and adjustment without requiring operators to access live electrical parts inside the converter, thereby maintaining safety while achieving calibration accuracy.
Data Source
AI summary
Disclosed is a method for calibrating an AC/DC converter with power factor correction, including the following steps: —connecting the input connector of the converter to a predetermined DC voltage power supply, such that this predetermined DC voltage is applied between the terminals of the input connector; —measuring, with a voltage measuring unit, the resulting calibration DC voltage which is delivered by the switching module when the predetermined DC voltage is applied between the terminals of the input connector; and —calibrating the voltage measuring unit by performing a calibration bringing the resulting calibration voltage back to the level of the predetermined DC voltage.