Solid-State Circuit Protection With AC-DC Conversion for Hazardous DC Loads
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Solution Overview
Problem
Conventional circuit protection devices for DC loads, such as LED luminaires, are prone to reliability issues and high costs due to integrated power converting circuitry, which can lead to overheating and reduced lifespan, and they often require explosion-proof enclosures that increase installation and maintenance complexity in hazardous environments.
Innovation Solution
A circuit protection device with integrated load controller and power converting circuitry that converts AC power to DC power, eliminating the need for individual power converters in LED luminaires, and uses solid state switches to provide circuit protection without mechanical contacts, allowing for safer operation in hazardous locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If integrated power converting circuitry is included in each LED luminaire, then the device can operate independently, but the reliability decreases due to heating and environmental susceptibility
Solution Approach 1:
The patent extracts the power converting circuitry from individual LED luminaires and relocates it to a centralized power supply unit. This removes the harmful heating effects from the luminaires themselves while maintaining the ability to convert AC power to DC power for driving the LED loads.
Solution Approach 2:
The patent combines the circuit protection device and power supply conversion functionality into a single integrated unit. This consolidation eliminates the need for separate explosion-proof enclosures and reduces overall system complexity while maintaining all necessary functions.
2Reliability
If solid state circuit breakers are used in hazardous locations, then circuit protection capability is improved, but the device complexity increases due to explosion-proof enclosure requirements
Solution Approach 1:
The patent merges the circuit protection device with the power supply conversion unit into a single integrated device. This combination eliminates the need for separate explosion-proof enclosures and reduces installation complexity while maintaining comprehensive circuit protection capabilities for DC loads.
Solution Approach 2:
The integrated device performs multiple functions simultaneously: AC to DC power conversion, circuit protection, and load control. This multi-functionality reduces the number of separate components needed and simplifies the overall system architecture for hazardous location applications.
3Adaptability or versatility
If multiple individual LED luminaires with integrated power converters are used, then each luminaire can operate independently, but the manufacturing cost and installation space increase
Solution Approach 1:
The patent extracts the power converting function from individual luminaires and centralizes it in a single power supply unit. This reduces manufacturing costs by eliminating redundant power converters and reduces installation space while maintaining the ability to drive multiple LED luminaire loads.
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
Reduces manufacturing costs and installation space while ensuring reliable and safe operation of DC loads in hazardous environments, without the need for separate explosion-proof enclosures, facilitating easier maintenance and compliance with safety standards.
Implementation Method 1
power converting circuitry operative to convert an alternating current (AC) power supply input to the line-side terminal to a direct current (DC) power output at the load side terminal
Data Source
AI summary
Hazardous location compliant solid state circuit protection device (100) includes at least one solid state switching element (142a-d) and a load controller (170). The solid state switching element operates in an arc-free manner to limit or preclude electrical current flow from the line-side terminal (132) to the load-side terminal (136). The load controller includes power converter circuitry (172) operative to convert an alternating current (AC) power supply input to the line-side terminal to a direct current (DC) power output at the load side terminal. One or more DC devices may be coupled to the DC power output at the load side terminal.