Power Supply Cell Switching for Wide Constant-Power DC Output

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Solution Overview

Problem

Conventional DC to DC power conversion systems face inefficiencies when trying to maintain a wide range of output voltage and current due to step drops in maximum output current when switching between series and parallel connections, limiting their ability to provide constant power across a broad voltage range.

Innovation Solution

A power supply cell and system that utilize multiple power conversion circuits, controllable semiconductor switches, and low-pass filters to smoothly control the series and parallel connections, allowing for linear extension of output voltage and current ranges through PWM modulation and the use of inductive elements in low-pass filters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional power supply systems switch between series and parallel connections to extend output voltage range, then the voltage range is enlarged, but the maximum output current experiences step drops at switching points

Engineering Contradiction:

Improveoutput voltage rangeVSAvoidmaximum output current continuity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies dynamics by transitioning from static switching between series and parallel connections to a dynamic continuous adjustment mechanism. The controllable semiconductor switches enable gradual transition between connection states, allowing the output current to change continuously rather than in discrete steps, thus resolving the step drop problem while maintaining extended voltage range capability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent introduces controllable unidirectional semiconductor switches as intermediary elements between the power conversion circuits and the output. These switches act as mediators that enable smooth, continuous control of current flow during transitions between series and parallel configurations, eliminating the abrupt current changes that occur in conventional direct switching approaches

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If traditional topology operates under wide output voltage range regulation, then the voltage range coverage is improved, but power efficiency deteriorates due to operation far from optimal point

Engineering Contradiction:

Improvevoltage range coverageVSAvoidpower efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent employs dynamic control through controllable semiconductor switches that allow the power conversion circuits to operate continuously at or near their optimal operating points across the entire voltage range. By enabling smooth transitions and continuous adjustment rather than fixed switching, the system maintains high efficiency while covering wide voltage ranges

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent utilizes parameter changes by dynamically adjusting the conduction states of controllable semiconductor switches to optimize operating parameters. This allows the system to adaptively change its operational characteristics to maintain optimal efficiency points across different output voltage conditions, rather than operating far from optimal as in traditional fixed topologies

Inventive Principle:

Principle #35Parameter changes

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

Enables a wide, linearly constant output power range by smoothing output voltage and current, maintaining high efficiency and power delivery from 200V to 1000V, with continuous constant full power output across the range.

Implementation Method 1

a first low-pass filter and a controlling unit operative to issue turn-on signal or turn-off signal to the first controllable unidirectional semiconductor switch so that the first power conversion circuit and the second power conversion circuit supply current to the low-pass filter

Methodology Applied

Scientific EffectLow-pass filtering: Filter (electronic)

Implementation Method 2

By controlling the ratio of series and parallel connection in a switching cycle of the switching frequency by the switching arrangement, both the output voltage and current range of the power supply cell can be enlarged smoothly and linearly with the help of the first low-pass filter

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11990749B2Power supply cell and power supply system using the same

Publication Date: 2024.05.21 ABB E-MOBILITY BV

AI summary

A power supply cell of a power supply system including a first power conversion circuit to output a first DC voltage, a second power conversion circuit to output a second DC voltage, a first controllable unidirectional semiconductor switch to generate a first conduction path from the first power conversion circuit to the second power conversion circuit, a first unidirectional semiconductor switch to generate a second conduction path from the first power conversion circuit to the second power conversion circuit, a second unidirectional semiconductor switch to generate a third conduction path from the first power conversion circuit to the second power conversion circuit, a first low-pass filter, and a controlling unit operative to issue turn-on signal or turn-off signal to the first controllable unidirectional semiconductor switch to supply current to the low-pass filter via the first conduction path or both of the second conduction path and the third conduction path.