Power Supply Synchronization Bus Using Optocoupler Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power supply systems for industrial applications face challenges in integrating parallel power structures due to limitations in communication, synchronization, and safety standards, including inefficiencies in interface signal management, potential common mode noise issues, and the need for costly reconfiguration upon failure of a master module, without non-volatile memory for system configuration or history.
Innovation Solution
A power supply system utilizing a synchronization bus with optocouplers, resistor ladders, and wire pairs to assert and read synchronization signals as current signals, enabling concurrent precharge and fault detection without a central controller, and providing galvanic isolation to prevent common mode noise, allowing for self-configuration and compliance with safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate system power supply is used for interface signals, then common mode noise issues are prevented, but cost and configuration complexity increase
Solution Approach 1:
The patent introduces optocouplers as intermediary devices between power supply modules to transfer synchronization signals. The optocouplers provide galvanic isolation, preventing common mode noise while allowing signal transmission through optical coupling. This resolves the contradiction by maintaining noise immunity without requiring a separate system power supply, thus reducing configuration complexity.
Solution Approach 2:
The patent replaces direct electrical connections (mechanical/electrical coupling) with optical coupling through optocouplers. This substitution eliminates the common mode noise pathway while maintaining signal transmission capability, achieving noise immunity without the complexity of a separate power supply system.
2Ease of operation
If one parallel power module is designated as master, then system coordination is achieved, but reconfiguration is required upon master failure
Solution Approach 1:
The patent implements a distributed synchronization protocol where each power supply module autonomously participates in synchronization through optocoupler-based signal exchange. Modules self-organize without requiring a designated master, and the system automatically adapts when modules are added or removed, eliminating reconfiguration requirements while maintaining coordination.
Solution Approach 2:
The synchronization system is designed to be dynamic and adaptive, allowing any module to assume synchronization leadership roles based on real-time system conditions. The optocoupler-based communication enables modules to dynamically adjust their operation, eliminating the static master-slave architecture and its associated reconfiguration needs.
3Device complexity
If DIP-switch settings are used for module configuration, then serial communication links are eliminated, but configuration flexibility is reduced
Solution Approach 1:
The optocoupler-based interface serves multiple functions: it provides galvanic isolation, enables synchronization signal transmission, and allows for flexible configuration. The same optical coupling infrastructure supports both fixed DIP-switch configurations and more flexible optically-mediated configuration methods, achieving multi-functionality that resolves the contradiction between simplification and flexibility.
4Device complexity
If pre-charging is performed open loop without current sensors, then system complexity is reduced, but synchronization precision deteriorates
Solution Approach 1:
The patent implements an optocoupler-based feedback mechanism where synchronization status is optically transmitted between modules. The optocouplers provide optical feedback about the synchronization state, enabling precise coordination of pre-charging operations without requiring current sensors. The optical coupling allows modules to sense and respond to each other's synchronization status, achieving precision without additional sensing hardware.
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
The solution enables efficient synchronization and fault handling between power supply modules, ensuring reliable operation, noise immunity, and compliance with safety standards, including N-1 operation without the need for a designated master module or separate interface power supply, and supports UL standard shutdown requirements.
Implementation Method 1
a first optocoupler for asserting a synchronization signal, a second optocoupler for reading a status of the synchronization signal
Data Source
AI summary
A power supply circuit for use with a power supply system. The power supply circuit can be provided within a power supply module connected with one or more additional power supply modules as part of the power supply system. The power supply circuit includes an optocoupler and a resistor ladder connected to the optocoupler. The circuit asserts a synchronization signal responsive to the optocoupler being energized.