Remote Power Controller Power Dissipation Reduction
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Solution Overview
Problem
Current remote power controllers (RPCs) face significant power dissipation issues due to semiconductor-based current limiting devices, which can dissipate hundreds of watts, requiring multiple devices in parallel, and existing 'helper' circuits only offer limited power reduction, typically less than 60% in practical scenarios.
Innovation Solution
A DC remote power controller design incorporating a current sensor, current limit controller, current limiting device, load resistance, and a switched-mode DC-to-DC converter that diverts load current through a load resistance to reduce power dissipation in the current limiting device while maintaining the load current at a reference level, using a switched-mode DC-to-DC converter to manage power dissipation by diverting current when potential difference exceeds predetermined levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semiconductor-based current limiting devices are used to limit load current, then current control is achieved, but power dissipation increases significantly
Solution Approach 1:
The current limiting function is segmented between two distinct components: the semiconductor-based current limiting device and the switched-mode DC-to-DC converter. The current limiting device handles current regulation while the converter manages power dissipation by diverting excess power, thereby resolving the contradiction between maintaining current control and reducing power loss.
Solution Approach 2:
The switched-mode DC-to-DC converter acts as an intermediary component that diverts excess load current from the semiconductor-based current limiting device. This intermediary mechanism allows the current limiting device to maintain its current control function while the converter absorbs and manages the excess power dissipation.
2Loss of energy
If multiple semiconductor-based current limiting devices are used in parallel to dissipate high power, then power dissipation capacity increases, but device complexity increases
Solution Approach 1:
The invention merges the current limiting function with a switched-mode DC-to-DC converter into a unified power management system. Instead of using multiple separate current limiting devices in parallel, the combined system achieves both current control and high power dissipation capacity through coordinated operation of the two components, thereby reducing overall device complexity.
3Loss of energy
If helper circuits are used to divert load current, then power dissipation in current limiting devices is reduced, but power reduction is limited to less than 60%
Solution Approach 1:
The switched-mode DC-to-DC converter employs dynamic control mechanisms to adjust its operation based on real-time power dissipation conditions. This dynamic approach enables the system to achieve up to 75% power dissipation reduction under ideal conditions, surpassing the static helper circuit limitation of less than 60% by actively optimizing current diversion based on system state.
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 reduces power dissipation in current limiting devices by up to 75% under ideal conditions and maintains load current regulation, significantly improving efficiency over existing designs.
Implementation Method 1
a current sensor for sensing the level of current that the power source supplies to the load and generating a current feedback signal representative of the sensed current level
Implementation Method 2
a switched-mode DC-to-DC converter in parallel with the current limiting device that senses potential difference across the current limiting device and diverts a portion of the load current from the current limiting device through the load resistance
Implementation Method 3
a current limiting device that is responsive to the current regulation signal to limit load current to the reference current level up to a first predetermined level of potential difference across the current limiting device
Data Source
AI summary
A direct current (DC) remote power controller for remotely controlling DC power between a DC power source and a DC load, comprises: a current sensor for sensing the level of current that the power source supplies to the load and generating a current feedback signal representative of the sensed current level; a current limit controller that compares the current feedback signal to a reference current level and generates a current regulation signal representative of the value of sensed current level above the reference current level; a current limiting device that is responsive to the current regulation signal to limit load current to the reference current level up to a first predetermined level of potential difference across the current limiting device; a load resistance; and a switched-mode DC-to-DC converter in parallel with the current limiting device that senses potential difference across the current limiting device and diverts a portion of the load current from the current limiting device through the load resistance above the first predetermined level of potential difference to reduce power dissipation of the current limiting device and maintain the load current at the reference current level.