Voltage Converter Controller with Automatic Mains Detection
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Solution Overview
Problem
Existing solutions for powering vacuum pumps across different AC mains supply conditions are costly and prone to electromagnetic compatibility (EMC) and thermal issues, with manual intervention often required to select the correct voltage, and voltage doublers are typically permanently enabled or require user selection, risking damage from incorrect settings.
Innovation Solution
A pump control module with dual AC mains detectors and switches that automatically enable or disable a voltage multiplier based on detected voltage ranges, providing a universal-voltage single-phase controller that switches between low and high voltage inputs without manual reconfiguration, ensuring safe and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a voltage doubler topology is permanently enabled, then the system can operate on low-voltage supplies, but the system may be damaged when connected to high-voltage supplies
Solution Approach 1:
The voltage doubler configuration is made dynamic through automatic switching based on detected mains voltage levels. The system transitions between enabled and disabled states of the voltage doubler depending on whether low-voltage (100-127Vac) or high-voltage (200-240Vac) mains supply is detected, allowing the same hardware to safely adapt to different voltage conditions without permanent configuration
Solution Approach 2:
The system incorporates voltage detection circuits that continuously monitor the mains supply voltage and provide feedback signals to control the switching of the voltage doubler. This feedback mechanism ensures the voltage doubler is only enabled when appropriate for the detected voltage level, preventing damage while maintaining operational versatility
2Reliability
If manual voltage selection is provided, then the correct voltage setting can be chosen, but customer intervention is required and errors may occur
Solution Approach 1:
The system performs automatic voltage detection and self-configures the voltage doubler setting based on the detected mains voltage level. No manual customer intervention is required - the voltage detection circuits automatically determine whether 100-127Vac or 200-240Vac is present and accordingly enable or disable the voltage doubler, eliminating both manual configuration steps and potential selection errors
3Reliability
If over-designed converter sub-systems are used, then the system can handle highest voltage and current, but the cost and device complexity increase
Solution Approach 1:
Instead of over-designing the converter to handle maximum voltage and current continuously, the system dynamically changes operational parameters by switching the voltage doubler on or off based on detected mains voltage. This allows the converter to be optimally sized for each voltage condition rather than being oversized for all conditions, reducing complexity and cost while maintaining reliability
Data Source
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AI summary
The present invention relates to a control module (1) for a voltage converter (3). The control module (1) has an input for connection to an AC supply (5) having an operating voltage range. A first detector (19) is provided for detecting the operating voltage range of the AC supply (5) and generating a first control signal (S1) to identify the detected operating voltage range. A second detector (21) is also provided for detecting the operating voltage range of the AC supply (5) and generating a second control signal (S2) to identify the detected operating voltage range. The control module (1) has one or more switches (39, 59) for selectively enabling and/or disabling a voltage multiplier (17) in response to said first and second control signals (S1, S2). The present invention also relates to a method of controlling a voltage converter (3).