Power Supply Device Current Limiting Resistor Startup Control

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Solution Overview

Problem

The existing power-supply devices for illumination systems face a challenge in suppressing high inrush currents during startup, as the current limiting unit is suspended before electric charges are sufficiently stored in capacitors, leading to excessive current flow.

Innovation Solution

A power-supply device with a current limiting unit and an adjustment unit that delays the activation of the current limiting resistor until a predetermined time period after the input voltage is started, ensuring the capacitor is charged adequately before limiting the input current.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the current limiting unit is suspended when the phase angle is within a predetermined range, then power loss is reduced during normal operation, but high inrush current flows at startup before the capacitor is sufficiently charged

Engineering Contradiction:
Improvepower lossVSAvoidinrush current
Core Design Contradiction:
Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by detecting the startup state before normal operation begins and activating the current limiting unit in advance during this initial period. The phase angle detection unit identifies when the AC voltage is in its initial half-cycle, and the control unit ensures the current limiting unit remains active during this predetermined time period. This preliminary activation prevents high inrush current from flowing into the uncharged capacitor before the charging process completes, while allowing the current limiting unit to be suspended later to reduce power loss during steady-state operation.

Inventive Principle:
Principle #10Preliminary action

2Object-affected harmful factors

If the current limiting unit is activated continuously, then inrush current is limited, but power loss increases during normal operation

Engineering Contradiction:
Improveinrush currentVSAvoidpower loss
Core Design Contradiction:
Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent implements periodic action by making the current limiting unit operate intermittently rather than continuously. The control unit suspends the current limiting unit during normal operation when phase angles indicate steady-state conditions, and activates it periodically during specific phases such as startup or when abnormal current conditions are detected. This periodic activation pattern maintains inrush current protection when needed while minimizing power loss during normal operation by keeping the current limiting unit suspended during non-critical periods.

Inventive Principle:
Principle #19Periodic action

3Productivity

If the current limiting unit is suspended early, then operational efficiency is improved, but the capacitor does not charge sufficiently leading to high inrush current

Engineering Contradiction:
Improveoperational efficiencyVSAvoidcapacitor charging
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies feedback by using the phase angle detection unit to continuously monitor the AC voltage phase angle and provide this information to the control unit. The control unit uses this feedback to determine whether to activate or suspend the current limiting unit. During startup, the feedback mechanism ensures the current limiting unit remains active until the capacitor has been sufficiently charged through the initial half-cycle, preventing premature suspension that would cause high inrush current. Once charging is complete, the feedback allows the control unit to suspend the current limiting unit for efficient operation.

Inventive Principle:
Principle #23Feedback

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 solution effectively prevents high inrush currents at startup, allowing the capacitor to be charged sufficiently before the current limiting function is activated, reducing power loss and ensuring stable operation of the illumination device.

Implementation Method 1

a rectifying unit configured to rectify a phase-controlled AC voltage

Methodology Applied
Scientific EffectRectification:

Implementation Method 2

electric charges are sufficiently stored in an electric storage portion, such as a capacitor, connected to a rear end of the current limiting unit

Methodology Applied
Scientific EffectCapacitance: Capacitance

Implementation Method 3

a current limiting unit including a current limiting resistor, which limits an input current flowing from the rectifying unit

Methodology Applied
Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS8988000B2Power supply device and illumination device
Publication Date: 2015.03.24 MINEBEAMITSUMI INC
  • US8988000B2 patent drawing
  • US8988000B2 patent drawing
  • US8988000B2 patent drawing

AI summary

A power-supply device includes a rectifying unit configured to rectify a phase-controlled AC voltage; a current limiting unit including a current limiting resistor, which limits an input current flowing from the rectifying unit at rise of a rectified voltage outputted from the rectifying unit; and an adjustment unit configured to cause the current limiting unit to limit the input current flowing from the rectifying unit until a predetermined time period has elapsed after an input of the AC voltage to the rectifying unit is started.