Ruggedized Programmable Power Switch with Multi-Source Balancing
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Solution Overview
Problem
Conventional DC-to-DC converters face challenges in efficiently managing multiple power sources with varying energy levels, leading to power coupling issues and requiring large transformers, which are cumbersome and costly. Additionally, existing solutions lack protection against harsh environments and improper handling, making them unsuitable for demanding conditions.
Innovation Solution
A programmable DC switch power supply that prioritizes multiple inputs, balances direct current loads, and provides a consistent output by adjusting and combining inputs from multiple DC-to-DC converter modules, housed in a ruggedized and sealed enclosure with heat dissipation capabilities, meeting military-grade specifications for environmental and electromagnetic considerations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transformer with separate windings for each input is used to accommodate multiple inputs, then any input can provide energy to any output with electrical isolation, but the transformer core becomes large and the design becomes cumbersome and costly
Solution Approach 1:
The patent divides the power conversion function into multiple independent DC-to-DC converter modules, each handling a specific input source. This segmentation eliminates the need for a single large transformer with multiple windings, as each module has its own isolated conversion path, thereby reducing overall transformer core size while maintaining input-output flexibility.
Solution Approach 2:
The patent employs a universal bus structure that can accommodate multiple DC input sources and DC outputs through standardized interfaces. This universal architecture allows any input to serve any output without requiring dedicated windings for each combination, achieving adaptability with a compact design.
2Adaptability or versatility
If multiple DC power sources are used to source DC power from one DC power source to another DC power source, then the capability to combine advantages of different energy sources is achieved, but the energy drawn from each source varies greatly due to load variations
Solution Approach 1:
The patent incorporates control circuits in each DC-to-DC converter module that monitor the state of multiple DC power sources and dynamically adjust conversion parameters. This feedback mechanism ensures stable energy distribution from each source by responding to load variations and source characteristics, preventing excessive variation in energy drawn from each source.
Solution Approach 2:
The patent uses programmable converters with adjustable duty cycles and conversion ratios that can dynamically adapt to changing load conditions and source characteristics. This dynamic control allows the system to optimize energy distribution stability by adjusting operating parameters in real-time based on actual system state.
3Ease of manufacture
If conventional housings are used to encase electronic components, then the device can be manufactured, but the housing is fragile and can be damaged by mistreatment and improper handling such as dropping
Solution Approach 1:
The patent employs composite housing structures combining rigid protective materials with shock-absorbing elements. This composite construction maintains ease of manufacturing while significantly improving durability and resistance to mistreatment, dropping, and environmental damage.
Solution Approach 2:
The patent incorporates shock-absorbing features and protective elements into the housing design before the device is subjected to stress. These pre-integrated cushioning elements protect fragile electronic components from damage during dropping or rough handling while maintaining manufacturing feasibility.
4Reliability
If the housing is ruggedized to protect electronic devices from environmental conditions and mistreatment, then protection from rain, dirt, dust, mud, snow, and water is achieved, but the size of the electronic device increases making transportation more cumbersome
Solution Approach 1:
The patent uses thin-film sealing layers and flexible protective coatings that provide environmental protection (against rain, dust, snow, water) without adding significant weight or bulk. These thin protective barriers maintain reliability while preserving device portability.
Solution Approach 2:
The patent integrates multiple protective functions (sealing, shock absorption, thermal management, environmental shielding) into a single unified housing structure. This multi-functional design achieves comprehensive environmental protection without proportionally increasing weight, as each protective feature serves multiple purposes simultaneously.
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 ensures reliable and consistent power output across varying input sources while protecting the electronics from environmental stressors and improper handling, enabling operation in extreme conditions with efficient heat management and reduced size and weight.
Implementation Method 1
A ruggedized programmable power switch having a thermally conductive mounting platform mechanically and thermally coupled to an electronic layer
Implementation Method 2
The tubular frame is configured as a heat sink having a plurality of exterior fins forming channels along a length of the tubular frame
Implementation Method 3
The tubular frame is configured as a heat sink having a plurality of exterior fins forming channels
Data Source
AI summary
A ruggedized programable switch accepts multiple forms of current from a plurality of sources and thereafter conditions and balances the current to provide a reliable common grounding plane of current for an end user. The common plane reduces electrical noise and interference through grounding loops preventing crosstalk between adjacent circuits while prioritizing current sources feeding the common plane. Components necessary to provide such a common plane of current are housed within a sealed, ruggedized protective housing. The housing passively conveys heat generated by the interiorly protected components to a plurality of heat dissipating fins and channels on the housing's exterior maintaining the device's operational capability. At the same time the housing protects the components from adverse environments and from adverse handling such as might be experienced in remote locations