Power Supply Online Upgrading With Continuous Output Switching
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Solution Overview
Problem
Conventional power supply systems require shutting down output during online upgrading, leading to increased costs and reduced flexibility and stability.
Innovation Solution
A method involving a master and secondary control chip that allows online power supply upgrading by turning off one transformer, sending upgrading instructions, and using a transmission protocol to ensure data correctness and synchronization, enabling continuous output without the need for a second power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one set of power supply is upgraded while the other set outputs power, then the power supply can maintain continuous output during upgrading, but the use cost of the power supply is greatly increased
Solution Approach 1:
The power supply system is divided into two independent control chips (first control chip and second control chip), each capable of independently controlling a transformer. This segmentation allows one chip to handle upgrading while the other maintains output, resolving the contradiction between continuous operation and cost reduction.
Solution Approach 2:
The patent implements a hot-swapping mechanism where control rights between the first and second control chips are dynamically transferred. During upgrading, the system temporarily discards the active control chip and recovers it after upgrading completes, allowing continuous operation without requiring permanent dual power supply redundancy.
2Productivity
If two sets of power supplies are used for online upgrading, then the power supply can be upgraded without shutting down output, but the power supply cannot be used flexibly and stability is reduced
Solution Approach 1:
Both the first control chip and second control chip are designed with identical functional capabilities, including voltage correction, current limiting, and protection functions. This universality allows either chip to take over during upgrading, providing flexibility in system operation and maintenance while maintaining stability.
Solution Approach 2:
The second control chip serves as a standby copy of the first control chip, with identical functionality but initially inactive. This copying approach enables online upgrading by switching to the copied chip while maintaining the original chip for upgrades, providing both productivity and flexibility.
3Ease of manufacture
If the power supply closes the output during online upgrading, then the upgrading process can be performed, but the power output cannot be simultaneously performed
Solution Approach 1:
The second control chip is pre-configured and ready before upgrading begins. The system performs preliminary setup of the standby chip including loading control parameters and establishing communication links, so that when switching is needed, the takeover is immediate and seamless, minimizing output interruption time.
Solution Approach 2:
The patent introduces a switching mechanism that acts as an intermediary between the first and second control chips. This mediator enables smooth transition of control during upgrading without requiring complete shutdown of output, allowing upgrading process simplicity while maintaining continuous power delivery.
Data Source
AI summary
An online upgrading method for a power supply, capable of enabling the power supply to simultaneously perform work output in the process of upgrading the power supply without using two sets of power supplies, and including: S1, determining whether the power supply needs to be corrected, and if the power supply needs to be corrected, sending an upgrading request to a master control chip; S2, the master control chip turning off any transformer in the power supply and sending a starting instruction to a secondary control chip, and the secondary control chip controlling the power supply to enter an upgrading mode according to the starting instruction; S3, when the power supply enters the upgrading mode, the power supply transmitting upgrading data to the secondary control chip by means of a transmission protocol.