Wire Harness Coordination for Parallel Power Supply Modules
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Solution Overview
Problem
Existing power supply systems for industrial applications face challenges in integrating parallel power structures due to limitations in communication, fault handling, and configuration management, which can lead to inefficiencies and increased costs.
Innovation Solution
A power supply system that includes multiple interconnected power supply modules connected via a wire harness with a synchronization bus and a fault bus, allowing for concurrent precharge, fault detection, and configuration verification without a central system controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate system power supply is used for interface signals, then common mode noise issues are avoided, but cost and configuration complexities increase
Solution Approach 1:
The patent introduces an intermediary isolated communication interface that mediates between power supply modules. This interface uses galvanic isolation to block common mode noise while maintaining signal transmission, avoiding the need for separate system power supplies and reducing configuration complexity.
Solution Approach 2:
The patent replaces the mechanical/electrical connection approach (direct wiring or separate power supplies) with an optical or magnetic field-based isolated communication interface. This substitution provides galvanic isolation to eliminate common mode noise while simplifying the overall system configuration.
2Ease of operation
If one power module is designated as master, then system coordination is achieved, but N-1 operation capability is lost requiring reconfiguration upon master failure
Solution Approach 1:
The patent implements dynamic role assignment where power modules can switch between master and slave roles automatically. The isolated communication interface enables dynamic negotiation of master-slave relationships, allowing the system to adapt when modules are added or removed, thereby achieving both coordination and N-1 operation capability.
Solution Approach 2:
The patent segments the master control functionality across multiple power modules rather than concentrating it in a single master. Each module retains the capability to function as master, and the isolated communication interface enables distributed coordination, allowing any module to take over master responsibilities if needed.
3Ease of manufacture
If DIP-switch settings are used for configuration, then hardware simplicity is maintained, but configuration time and potential for errors increase
Solution Approach 1:
The patent replaces mechanical DIP-switch configuration with electronic configuration methods. The isolated communication interface enables digital communication between modules, allowing configuration parameters to be set and transmitted electronically, thereby reducing configuration time and eliminating manual switching errors while maintaining hardware simplicity.
4Power
If all power modules are interconnected for parallel operation, then power capacity is increased, but fault propagation risk and synchronization complexity increase
Solution Approach 1:
The patent introduces the isolated communication interface as an intermediary between parallel power modules. This interface provides galvanic isolation that prevents fault propagation between modules while maintaining communication for coordination. The isolation barriers ensure that faults in one module do not directly affect other modules, thereby maintaining reliability while enabling parallel power operation.
Data Source
AI summary
A power supply system includes modular power supply modules interconnected via a wire harness. The power supply system can be installed in one or more electrical cabinets in a manufacturing facility, for example, among other possible applications. The wire harness includes a fault bus and a synchronization bus, and the individual power supply modules detect and report faults as well as synchronize operation, such as pre-charging, via communication using the wire harness.