Vehicle Power Converter Activation Circuit Design
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Solution Overview
Problem
Existing power converters for electrical vehicles face increased manufacturing costs due to the need for high-voltage components in switching circuits and longer wiring lengths for activation signals, especially when activating control circuits with low-voltage power supplies.
Innovation Solution
A power converter design that includes a converter circuit, a control circuit, and an activation circuit, where the activation circuit determines the receipt of an activation signal based on voltage between input terminals, allowing the control circuit to be activated without extending the wiring length for the activation signal, using a low-voltage power supply and components like FETs and photocouplers to manage the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the switching circuit is activated upon application of high DC voltage to activate the switching circuit, then the switching circuit can be activated, but high-voltage components are required which increases manufacturing costs
Solution Approach 1:
The patent introduces an activation circuit as an intermediary between the high-voltage main power supply and the control circuit. This activation circuit uses a voltage divider circuit to generate a low-voltage activation signal from the high voltage, which then triggers the control circuit without requiring it to directly withstand high voltage. This mediator approach allows the control circuit to be activated reliably while using only low-voltage components, resolving the contradiction between reliable activation and manufacturing cost.
2Ease of manufacture
If the accessory power supply is used to activate the switching circuit, then the switching circuit can be activated with low voltage, but the wiring length increases which increases manufacturing costs
Solution Approach 1:
The patent merges the activation signal generation function into the activation circuit itself, which is electrically connected to the input terminals of the converter circuit. The voltage divider circuit within the activation circuit directly taps into the high-voltage input to generate the activation signal, eliminating the need for separate wiring from the accessory power supply. This merging of functions reduces wiring length while maintaining low-voltage activation capability.
3Reliability
If the activation circuit is placed far from the main switch to activate the control circuit, then the control circuit can be activated, but the wiring length for conveying activation signal increases which increases manufacturing costs
Solution Approach 1:
The activation circuit is designed to be self-sufficient by incorporating the voltage divider circuit that directly extracts the activation signal from the high-voltage input terminals. This eliminates the need for external wiring to convey activation signals from distant locations. The activation circuit serves itself by generating its own activation signal locally, resolving the contradiction between reliable activation and minimized wiring length.
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
This design reduces manufacturing costs by eliminating the need for lengthy wiring and ensures reliable activation of the control circuit, maintaining electrical connection despite voltage variations and potential switching noise, while allowing flexible placement of drive circuits.
Implementation Method 1
a photocoupler to activate the control circuit
Data Source
AI summary
A power converter capable of activating a control circuit therein without increasing a length of a wiring for conveying an external activation signal. In the power converter, a converter circuit isolates a first voltage of a first power supply, converts the first voltage into a second voltage, and outputs the second voltage to a second power supply. A first power supply connecting circuit connects the first power supply to the converter circuit in response to the activation signal. An activation circuit determines whether or not the activation signal has been received by the first power supply connecting circuit on the basis of a voltage between input terminals of the converter circuit and activates the control circuit when it is determined that the activation signal has been received by the first power supply connecting circuit.