UPS Load Simulation for Electrical Testing
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Solution Overview
Problem
Existing uninterruptible power supply systems cannot perform electrical tests that include a power receiving board on the input side and a bus board on the output side while operating normally without connecting a simulated load, limiting the evaluation of the system's functionality and performance.
Innovation Solution
The system includes multiple uninterruptible power supplies connected in parallel, with each supply switching between normal operation and load simulation modes, allowing a closed circuit to be formed for testing without a simulated load, using rectifiers, inverters, and bypass circuits, and controlled by a controller to manage the switching and interlocking signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a closed circuit is constructed via the converter, inverter and bypass circuit for electrical testing, then the electrical test can be performed without separately connecting a load device, but an electrical test including a power receiving board on the input side and a bus board on the output side cannot be performed
Solution Approach 1:
The system divides the testing function by designating specific UPS units as load simulation units that separately simulate load characteristics. This segmentation allows the power receiving board and bus board to be included in the test circuit without requiring all UPS units to form a closed circuit, thereby enabling comprehensive electrical tests while maintaining ease of implementation.
Solution Approach 2:
The invention introduces a load simulation unit as an intermediary component that mimics load characteristics. This intermediary enables the construction of a test circuit including the power receiving board and bus board by providing the necessary current flow path without requiring actual external loads, thus expanding test coverage while keeping the system self-contained.
2Measurement precision
If the inverter operates by voltage waveform control in original product operation, then the distortion factor, voltage accuracy and response can be specified, but the frequency and voltage value of the load waveform are limited to values of AC input
Solution Approach 1:
The load simulation unit dynamically adjusts its output waveform characteristics based on control signals from the control unit. This dynamic capability allows the system to simulate various load conditions with different frequencies and voltage values while maintaining voltage accuracy through controlled operation, thereby achieving both precision and flexibility.
Solution Approach 2:
The invention enables parameter changes by allowing the load simulation unit to vary frequency and voltage values independently of the AC input values. The control unit regulates these parameters to maintain voltage accuracy while providing the flexibility to test different waveform conditions, thus resolving the contradiction between precision and adaptability.
3Adaptability or versatility
If multiple uninterruptible power supplies are connected in parallel and switched between normal operation mode and load simulation mode, then comprehensive testing can be performed without simulated load, but the system complexity increases
Solution Approach 1:
Each UPS unit is designed with multi-functionality, capable of operating in both normal operation mode and load simulation mode. The control unit manages the switching between these modes, allowing any UPS unit to serve dual purposes. This universality enables comprehensive testing capabilities while avoiding the need for separate dedicated test equipment, thus managing system complexity.
Solution Approach 2:
The system performs self-testing by having UPS units simulate loads for each other. The load simulation units generate test currents that flow through the power receiving board and bus board, enabling the system to test itself without external equipment. This self-service approach expands test capability while minimizing additional system complexity.
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 comprehensive testing, including load fluctuation and AC source power failure tests, while maintaining normal operation, improving output current balance and suppressing voltage drops, and reducing energy losses during testing.
Implementation Method 1
a rectifier to convert the AC power from the power receiving board (2) into DC power
Implementation Method 2
an inverter to convert the DC power from the rectifier (11) into AC power to supply the converted AC power to the bus board (3)
Data Source
AI summary
An uninterruptible power supply system includes a plurality of uninterruptible power supplies, each of which includes a rectifier and an inverter and switches between a normal operation mode for normal operation and a load simulation mode for simulating a load.