Multi-Stage UPS Connector Reduces Inrush Current
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Solution Overview
Problem
Traditional connectors for power sources often lack flexibility and efficiency in connecting power and signal circuits simultaneously due to limited available contacts, leading to issues with inrush current and arcing when connecting devices to power sources, especially with battery-supplied sources.
Innovation Solution
A multi-stage connection method using three contacts to efficiently couple power and signal circuits, where the first contact and second contact form a current limiting circuit in the first stage, and the first contact and third contact form a power circuit, while the second contact and third contact form a signal circuit in a second stage, allowing controlled charging and reduced inrush current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional connectors with limited contacts are used to connect power source to device, then the connector structure is simple, but the flexibility to connect both power and signal circuits simultaneously is reduced
Solution Approach 1:
The connection process is divided into two distinct stages: a first stage where initial contacts establish basic power connection, and a second stage where additional contacts are engaged to enable signal circuit connection. This temporal segmentation allows the same physical connector to support multiple circuit types without requiring simultaneous engagement of all contacts.
Solution Approach 2:
The power circuit is connected in advance during the first stage before the signal circuit is connected in the second stage. This preliminary action ensures that power is available to energize signal processing circuits before they become operational, and allows for controlled inrush current management before full system activation.
2Power
If power source is connected directly to device with large capacitance, then power transfer is efficient, but inrush current causes arcing that damages contacts
Solution Approach 1:
A precharge circuit is activated in the first stage to gradually charge the device capacitance before full power connection. This preliminary charging action reduces the voltage differential at the moment of full connection, thereby limiting inrush current and preventing harmful arcing while still enabling efficient power transfer subsequently.
Solution Approach 2:
The precharge circuit acts as an intermediary between the power source and the device capacitance. It provides a controlled current path that limits inrush current, protecting the connector contacts from arcing damage while still enabling the capacitor to be charged to the required voltage level before full power connection.
3Reliability
If multiple circuits are connected using separate connectors, then each circuit connection is reliable, but the overall system complexity and connection time increase
Solution Approach 1:
Multiple circuits (power circuit and signal circuit) that would traditionally require separate connectors are merged into a single connector assembly. This consolidation allows both circuits to be connected simultaneously in one physical action, reducing connection time while maintaining the reliability of individual circuit connections through dedicated contacts for each circuit type.
Solution Approach 2:
Within the unified connector, different contacts are segmented and assigned to different circuits (power vs. signal). This internal segmentation allows independent connection paths for each circuit type, ensuring that reliability requirements for each circuit are met while benefiting from the time savings of simultaneous connection.
Data Source
AI summary
According to one aspect of the invention, an uninterruptible power supply includes UPS circuitry, a power source adapted to couple to the UPS circuitry, a first contact, a second contact, and a third contact. The first contact, the second contact, and the third contact are adapted to couple the UPS circuitry to the power source. In a first stage of connection of the UPS circuitry and the power source, the first contact and the second contact are employed in a first circuit. In a second stage of connection of the UPS circuitry and the power source, the first contact and the third contact are employed in a second circuit, and the second contact and the third contact are employed in a third circuit.