Series Voltage Regulators for Overvoltage Protection
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Solution Overview
Problem
Existing electrical functional groups in measuring devices fail to maintain intended function during overvoltage events without compromising functional safety, as they often require a single voltage regulator that can be overwhelmed by voltage differences between the supply source and the control device's voltage range.
Innovation Solution
Incorporating a second voltage regulator connected in series with the first voltage regulator, allowing power to be drawn from the supply voltage source through both regulators, which are designed as low-dropout series regulators to minimize power loss and maintain operational voltage within safe ranges, even in the event of overvoltage failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single voltage regulator is used to step down voltage from the supply source to the control device, then the device complexity is reduced, but the reliability decreases because the regulator becomes overwhelmed by large voltage differences and fails during overvoltage events
Solution Approach 1:
The voltage regulation function is segmented into two separate voltage regulators connected in series. The first voltage regulator steps down the supply voltage to an intermediate voltage level, and the second voltage regulator further steps down the intermediate voltage to the control device's operating voltage. This segmentation distributes the voltage reduction task, preventing any single regulator from being overwhelmed by large voltage differences, thereby improving reliability during overvoltage events while maintaining reasonable device complexity
2Adaptability or versatility
If the voltage regulator is designed to handle large voltage differences, then the adaptability to different supply voltages is improved, but the object-generated harmful factors increase due to excessive power dissipation and heat generation
Solution Approach 1:
The power dissipation burden is segmented between two voltage regulators. Each regulator handles a smaller voltage difference individually, reducing the power loss (P = V × I) in each regulator compared to a single regulator handling the entire voltage drop. This segmentation maintains adaptability to different supply voltages while significantly reducing harmful power dissipation and heat generation in each regulator stage
3Ease of manufacture
If a single voltage regulator is used, then the ease of manufacture is improved, but the loss of time increases because the entire functional group must be switched off during overvoltage faults
Solution Approach 1:
The voltage regulation system is segmented into two independent regulators, creating functional redundancy. When an overvoltage fault occurs, the control device can switch off only the affected regulator while the other regulator continues to operate and maintain voltage supply. This segmentation enables partial operation during faults, reducing operational downtime while maintaining manageable manufacturing complexity through standardized regulator modules
Data Source
Figure 1
Figure 2
AI summary
The diagram shows an electrical functional group (2) comprising a control device (4) and a first voltage regulator (5), wherein the control device (4) has a supply voltage input (7), and wherein the first voltage regulator (5) has a first supply voltage input (12) and a first supply voltage output (13), is configured for connection to a supply voltage source (3) via the first supply voltage input (12) and for supplying the control device (4) via the first supply voltage output (13), and wherein the first supply voltage output (13) and the supply voltage input (7) of the control device (4) are connected to each other. The invention is based on the objective of providing a functional group (2) in which the intended function is maintained even in the event of a fault, without impairing functional safety.The problem is solved by the functional group (2) having a second voltage regulator (6) with a second supply voltage input (15) and a second supply voltage output (16), by the second voltage regulator (6) being designed for connection to the supply voltage source (3) via the second supply voltage input (15) and for supplying the first voltage regulator (5) and the control device (4) via the second supply voltage output (16), and by the second supply voltage output (16) and the first supply voltage input (12) being connected to each other.