SMPS Start-Up via Network Wiring Under Wide DC Bus Voltages

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Solution Overview

Problem

Existing switch mode power supplies face challenges in starting up efficiently from a wide range of DC bus voltages, particularly when incorporating functional safety features that limit supply voltage under fault conditions.

Innovation Solution

The technology provides an efficient apparatus for starting up switch mode power supplies by supplying start-up power to a PWM regulator circuit via network wiring, while being voltage limiting to enable safe operation of safety circuitry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If switch mode power supply operates from wide range of DC bus voltages (45V to 900V), then adaptability is improved, but reliability deteriorates due to difficulty in creating voltage limiting start-up circuit under fault conditions

Engineering Contradiction:

Improveoperating voltage rangeVSAvoidsafety circuit operation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent introduces an intermediary start-up power supply circuit that mediates between the wide voltage range DC bus and the safety-critical PWM regulator circuit. This intermediary circuit actively regulates the start-up voltage to a limited safe level, preventing direct connection of the wide voltage range to safety circuits while enabling operation across the full 45V to 900V bus voltage range.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the voltage parameter dynamically through an active regulation circuit that adjusts the start-up voltage level based on the DC bus voltage. The circuit transforms the wide voltage range (45V-900V) into a constrained safe voltage range for the PWM regulator, allowing the system to adapt to different bus voltages while maintaining safety limits.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If voltage limiting is implemented in start-up circuit to protect safety circuitry, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvesafety circuit protectionVSAvoidstart-up circuit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The start-up power supply circuit is designed to be self-regulating, automatically limiting its own output voltage to safe levels without requiring external supervision circuits. The circuit inherently provides voltage limiting through its regulation mechanism, eliminating the need for additional safety supervision components and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent combines the voltage limiting function with the start-up power supply function into a single integrated circuit. Rather than adding separate voltage limiting components to an existing start-up circuit, the design merges these functions, creating a unified start-up power supply that inherently provides both start-up capability and voltage protection.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate control power port is provided for motor drives, then reliability is improved, but ease of operation deteriorates due to multiple power connections required

Engineering Contradiction:

Improvepower supply independenceVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The DC bus serves multiple functions: it provides both the high voltage power for motor operation and the start-up power for control electronics through the same connection. The single DC bus connection is designed to fulfill dual purposes, eliminating the need for separate control power ports and simplifying installation while maintaining reliable power supply for both motor and control functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the high voltage power connection and control power connection into a single DC bus interface. Instead of requiring separate cables and connectors for motor power and control power, the design combines these functions through one unified power connection, reducing installation complexity while ensuring reliable power delivery to both systems.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for reliable and efficient start-up of switch mode power supplies across a wide range of voltages, ensuring safe operation of safety circuitry even under fault conditions.

Implementation Method 1

supplying start-up power to a PWM regulator circuit of a switch mode power supply of a device via network wiring

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS12206334B2Networked automation system for start-up of a switch mode power supply

Publication Date: 2025.01.21 KOLLMORGEN CORP

AI summary

Networked automation systems having electric actuation from a high voltage source. The electric actuator includes a switch mode power supply coupled to the high voltage source as a principal power source. The networked automation systems include a controller device having an output network port wired to an input network port of the motor drive. The controller device is also coupled to an auxiliary source of power. Thus, a regulation circuit of the switch mode power supply can be coupled to the auxiliary source of power, thereby providing power for the regulation circuit at start up.