Switched-In Voltage Doubler for Wide-Range Constant Power Charging
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Solution Overview
Problem
Existing power supplies face challenges in providing an adequate charging profile at higher voltages, requiring significant redesign and increased complexity and cost to achieve consistent output power, especially when charging capacitors for high-energy applications like lasers.
Innovation Solution
A power supply system that monitors output voltage and switches secondary windings and capacitors in series or parallel based on voltage thresholds, allowing for a constant output power range from 0V to at least twice the second threshold without major redesign or component replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power supply voltage is increased to charge capacitors for high-energy applications, then output power capability is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The power supply output stage is segmented into multiple parallel rectifier bridges, each capable of operating independently. This allows the system to achieve high voltage capability by combining multiple lower-voltage rectifier units in parallel, rather than using a single high-voltage rectifier, thereby reducing complexity and cost while maintaining power capability.
Solution Approach 2:
The parallel rectifier configuration enables each rectifier bridge to serve multiple functions: they can operate independently for voltage sharing, work together for increased current capability, and provide redundancy for reliability. This multi-functionality allows the same hardware architecture to achieve both high power capability and reduced complexity.
2Power
If power supply voltage is increased to charge capacitors for high-energy applications, then output power capability is improved, but manufacturing cost increases
Solution Approach 1:
By dividing the power supply into multiple identical parallel rectifier modules, the manufacturing process becomes more standardized and scalable. Each module can be manufactured using the same components and procedures, reducing per-unit cost while achieving high overall power capability through parallel operation.
Solution Approach 2:
The patent employs standard, readily available rectifier bridge components rather than custom high-voltage specialized components. This approach uses inexpensive, off-the-shelf parts that can be easily replaced if needed, reducing manufacturing cost while achieving the required power capability through proper parallel configuration.
3Productivity
If charging time is reduced to improve productivity, then output power delivery is improved, but voltage stability and charging profile consistency deteriorate
Solution Approach 1:
The parallel rectifier configuration segments the current delivery path into multiple independent channels. This allows the system to deliver high total current (improving charging speed) while each individual rectifier channel maintains stable voltage output, preventing the voltage instability that would occur with a single high-current path.
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
Enables a compact and cost-effective power supply to provide consistent output power over a wide voltage range, reducing complexity and costs by minimizing changes to transformer windings and components.
Implementation Method 1
a transformer coupled between an input end and the output end of the power supply, the transformer including a single primary winding and the plurality of secondary windings
Implementation Method 2
SMPS' may utilize energy storage elements (e.g., capacitors and/or inductors) to store energy during one part of a high-frequency switching cycle, and release said energy during another part of the high-frequency switching cycle
Data Source
AI summary
This disclosure describes systems, methods, and apparatuses for a power supply, the power supply configured for monitoring a voltage at an output end of the power supply; controlling, based on the voltage exceeding a first threshold, a first switch to connect a plurality of secondary windings of the power supply in series; and controlling, based on the voltage exceeding a second threshold, at least one other switch to switch in at least one capacitor into the power supply, wherein the second threshold is greater than the first threshold.