Universal Power Supply Parallel Modules AC Input
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power supplies for plasma arc systems are limited in providing high DC output currents from a wide range of AC power source inputs, requiring large and costly isolation transformers and components, which restrict their use in accommodating various AC power inputs effectively.
Innovation Solution
A universal power supply design featuring multiple power modules connected in parallel, each comprising a rectifier, converter, inverter, and power module controller, with a master controller regulating the DC output current by controlling individual power module controllers, allowing efficient operation across a wide range of AC inputs without the need for large isolation transformers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large front end isolation transformer with multiple taps or multiple transformers is used to accommodate various AC power supply inputs, then the power supply can accept different AC voltages, but the inventory and costs increase
Solution Approach 1:
The power supply system uses a single isolation transformer design that can universally handle multiple AC input voltages (200V-600V) through a unified circuit topology. The system achieves multi-functionality by combining the isolation transformer with a converter circuit that includes controllable rectifiers and switching devices, allowing one transformer to serve multiple voltage requirements without needing separate transformers for each voltage level.
2Power
If higher rated power devices such as higher rated fast recovery diodes, IGBTs and high frequency magnetics are used to increase output current rating, then the output DC current rating increases, but the costs increase
Solution Approach 1:
The power supply system segments the power processing function into distinct stages: the isolation transformer handles voltage transformation and isolation, while the converter circuit with controllable rectifiers and switching devices handles current regulation and output control. This segmentation allows each component to be optimized for its specific function rather than requiring all components to handle the full power rating, reducing overall system cost while maintaining high output current capability.
3Device complexity
If converter circuits are used to avoid large front end isolation transformers, then the inventory and costs decrease, but the output DC current rating is limited
Solution Approach 1:
The system merges the isolation transformer with the converter circuit into an integrated power supply system. The isolation transformer is combined with controllable rectifiers, switching devices, and control circuits to create a unified system where the transformer enables high power capability while the converter circuit provides universal input voltage acceptance. This merging allows the system to achieve both high output DC current rating and adaptability to various AC inputs without requiring separate large transformers for each function.
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 enables the provision of high DC output currents efficiently from various AC power sources, reducing component costs and inventory, and allowing a single universal power supply to be used across different plasma arc applications, leading to cost savings and increased efficiency.
Implementation Method 1
a rectifier configured to receive the AC input and provide a rectified voltage
Implementation Method 2
a converter circuit coupled to the rectifier and configured to convert the rectified voltage to a different DC voltage level
Implementation Method 3
an inverter coupled to the converter and configured to convert the different DC voltage level back to an AC voltage
Implementation Method 4
an isolation transformer coupled to the inverter and configured to provide an isolated AC output
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A universal power supply for use in a plasma arc system is disclosed. The power supply can include a plurality of power modules for providing a DC output from an AC input. Each of the power modules can include a rectifier, a converter, an inverter, an isolation transformer and an output rectifier. The power modules can include a power module controller configured to control at least one of the rectifier, the converter, or the inverter such that a DC output can be obtained from a wide variety of AC inputs. The power modules can be connected in parallel to provide a wide range of DC output currents for the power supply. The universal power supply can include a master controller coupled to each of the individual power module controllers to regulate the DC output current of the power supply by controlling the individual power module controllers.