Relay-Bypass Surge Suppression Circuit for EV Power Startup
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Solution Overview
Problem
In high-current power supply modules for electric vehicles, the relay is completely controlled by a hardware circuit, leading to potential damage due to component failures and the generation of surge currents during switch-on, necessitating a circuit structure to prevent surge currents.
Innovation Solution
A circuit that includes a power supply module, a relay connected in parallel with a variable resistance, a voltage detection module, and a microcontroller, which controls the relay and variable resistance to manage the power supply, reducing the risk of damage by adjusting the voltage based on detected output voltage levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relay is completely controlled by a hardware circuit, then the control is simple and reliable, but the relay cannot function properly due to damages to any component in the hardware control circuit
Solution Approach 1:
The patent replaces the purely hardware-based mechanical control system with a software-controlled system. The microcontroller executes control logic to manage the relay, substituting the mechanical hardware control circuit with a programmable software-based control mechanism, thereby improving reliability by avoiding hardware component failures.
Solution Approach 2:
The patent introduces a microcontroller as an intermediary between the power supply module and the relay. This intermediary component coordinates the control signals and manages the relay operation, isolating the relay from direct hardware circuit control and enabling more robust error handling and protection mechanisms.
2Productivity
If a switch is powered on, then the power supply starts operating, but a high surge current is generated
Solution Approach 1:
The patent applies preliminary action by pre-charging the capacitor through the variable resistance before the main power switch is fully closed. This preliminary charging phase limits the inrush current, and only after the capacitor is sufficiently charged does the control logic close the main switch, thereby preventing surge current while maintaining quick startup.
Solution Approach 2:
The patent uses a variable resistance that dynamically changes its resistance value during the startup process. Initially, the resistance is high to limit surge current, and as the power supply stabilizes, the resistance decreases or is bypassed entirely, allowing full power operation. This dynamic adjustment resolves the contradiction between fast startup and surge current limitation.
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 circuit effectively suppresses surge currents, ensuring the normal operation of components and improving the stability and durability of the surge protection system by reducing the likelihood of relay failure and component damage.
Implementation Method 1
a variable resistance, and the relay is connected in parallel to the variable resistance and then connected between an external power supply and the power supply module
Implementation Method 2
the relay is connected in parallel to the variable resistance and then connected between an external power supply and the power supply module
Data Source
AI summary
The present disclosure provides a circuit and method for suppressing a power supply starting surge, a charging apparatus, and a storage medium. The circuit for suppressing a power supply starting surge includes: a power supply module, a relay, and a variable resistance. The relay is connected in parallel to the variable resistance and then connected between an external power supply and the power supply module. According to the present disclosure, the variable resistance is connected in parallel to both ends of the relay, so that a power supply starting surge can be effectively suppressed, the power supply module is controlled to output an appropriate power supply voltage, and normal operation of components in the circuit can be protected.