Dual-DC-Bus UPS Converter Integrating PFC and Backup DC/DC
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Solution Overview
Problem
Traditional online UPS topologies have a high component count, increased cost, and reduced power density due to the use of separate Power Factor Correction (PFC) converters for AC power and DC/DC converters for backup power, leading to complexity and inefficiency.
Innovation Solution
A multi-function converter is introduced that can selectively couple to both input AC power and backup DC power, operating as a PFC boost converter during AC power availability and a boost/buck-boost converter during backup power usage, eliminating the need for separate converters and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate PFC converters and DC/DC converters are used for AC power and backup power respectively, then power conversion functionality is ensured, but device complexity and component count increase
Solution Approach 1:
The patent implements a universal converter that can operate in multiple modes: PFC boost converter mode for AC power processing and DC/DC converter mode for backup power processing. The converter includes switches, diodes, inductors, and capacitors that are configured through control circuitry to perform different conversion functions, eliminating the need for separate dedicated converters and reducing overall system complexity
Solution Approach 2:
The patent merges the functionality of separate PFC converters and DC/DC converters into a single integrated converter unit. The converter shares common components such as inductors, capacitors, and control circuitry between AC power processing and backup power processing functions, thereby reducing component count and device complexity while maintaining full power conversion capability
2Adaptability or versatility
If separate PFC converters and DC/DC converters are used, then power conversion is ensured, but manufacturing cost increases
Solution Approach 1:
The universal converter design allows a single converter module to replace multiple dedicated converter modules, reducing the total component count and manufacturing cost. The converter can be manufactured as a standardized unit with configurable operation modes, simplifying the manufacturing process and reducing assembly costs
Solution Approach 2:
By merging AC power processing and backup power processing functions into a single converter, the patent reduces the number of separate components that need to be manufactured, procured, and assembled. This consolidation leads to lower material costs, reduced assembly complexity, and overall lower manufacturing costs
3Adaptability or versatility
If separate converters are used for AC and backup power, then power conversion is ensured, but power density is reduced
Solution Approach 1:
The universal converter consolidates multiple power conversion functions into a single compact unit, eliminating redundant components and reducing overall system volume and weight. This multi-functional design maintains full power conversion capability while improving power density by removing unnecessary duplication of converter components
4Adaptability or versatility
If separate PFC converters and DC/DC converters are used, then power conversion functionality is ensured, but system efficiency decreases
Solution Approach 1:
The integrated converter reduces energy losses by eliminating redundant power conversion stages and components. By using a single converter that can switch between PFC and DC/DC modes, the system avoids the energy losses associated with multiple separate converters and their interconnections, thereby improving overall system efficiency
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 results in a more cost-effective and compact UPS topology with increased power density by providing DC power from either AC or backup DC sources, minimizing unused components and maintaining power quality during transitions.
Implementation Method 1
a converter circuit (204) having an inductor (224) and a first end (224a) of the inductor (224) coupled to a neutral connection (205)
Data Source
AI summary
An Uninterruptible Power Supply (UPS) including an input configured to receive input AC power, a backup power input configured to receive backup DC power having a first voltage level from a backup power source, a converter configured to convert the input AC power from the input and the backup DC power from the backup power input into DC power having a second voltage level, the converter including an input selection circuit configured to selectively couple the converter to the input and the backup power input, an inductor, a first converter switch configured to couple a first end of the inductor to a neutral connection, and a second converter switch configured to couple a second end of the inductor to the backup power input via the input selection circuit.