WO2008102984A1

WO2008102984A1 - Power conversion system and method

Info

Publication number: WO2008102984A1
Application number: PCT/KR2008/001000
Authority: WO
Inventors: Yeon Tae Ha
Original assignee: Yeon Tae Ha
Priority date: 2007-02-21
Filing date: 2008-02-20
Publication date: 2008-08-28
Also published as: JP2010519534A

Abstract

Disclosed is an integrated process system for power conversion and characteristic test in that the electric powers can be recycled and cut down in a durability test and the durability test and the characteristic test for confirming the quality of each power supply can be performed at the same time, thereby reducing the entire manufacturing process. Accordingly, the DC output powers of each power supply consumed in the form of thermal energy through a load for durability test is converted into the AC power of 110-220 Vac and the converted Ac power can be recycled so as to perform the durability test, thereby remarkably reducing the electric powers used in the entire manufacturing process.

Description

Description POWER CONVERSION SYSTEM AND METHOD

Technical Field

[1] The present invention relates to an integrated process system for power conversion and characteristic test, and more particularly to an integrated process system for power conversion and characteristic test in that the electric powers can be recycled and cut down in a durability test and the durability test and the characteristic test for confirming the quality of each power supply can be performed at the same time, thereby reducing the entire manufacturing process. Background Art

[2] Presently, a power converter such as a power supply (including an inverter) etc., which is a core part in an electric product or part manufacturing market, tests for the durability thereof for several hours before delivery. Also, the products of finishing the durability test for the characteristic process so as to confirm as to whether the durability test is passed or not.

[3] Because of the mass production, several hundreds to several thousands power supplies test for the durability at the same time. The durability test thereof is performed for about 4 hours and the tester for durability is continually operated for 24 hours.

[4] FIG. 1 is a schematic block diagram illustrating a conventional durability tester of the power supply used in a manufacturing process of the power supply.

[5] As shown in FIG. 1, an AC power of 110Vac-220Vac is supplied to each power supply for testing the durability thereof and then, it confirms as to whether a DC power output is continually generated for a predetermined time (at least four hours) or not. In order to induce the DC power output from the corresponding power supply during the durability test, a load is applied to each output terminal of each power supply.

[6] However, in the conventional durability test of the power supply, there is a problem in that the electric powers are consumed in the form of a thermal energy owing to the load applied to each output terminal of each power supply for inducing the DC power output. Also, since the stable DC output on the AC input power of the power supply is continually maintained in course of the durability test, the load is positively necessary during the durability test.

[7] Presently, a watt resistance of high electric power is electrically connected to the load, so that the DC output powers converted in each power supply are consumed in the form of thermal energy. Accordingly, since the DC output powers of each power supply are consumed in the form of thermal energy by using the watt resistance of high electric power as described above, there is a problem in that the temperature of the inside of the laboratory is very high. In order to drop the temperature thereof, it is necessary to operate an air conditioner etc., thereby generating a second wasted energy.

[8] For this reason, the bulk of the electric powers are consumed in the durability test among the manufacturing processes of the power supply, thereby highly increasing the manufacturing cost thereof.

[9] Also, since the information on the quality of each power supply cannot be obtained during the durability test, there is another problem in that a separate characteristic test on the power supply of finishing the durability test should be performed so as to confirm as to whether the durability test is passed or not. Accordingly, in the present invention, the DC output powers outputted from each power supply in course of the durability test can be obtained through a current sensor at a predetermined interval (capable of fixing according to the condition of the power supply), so that the information on the quality of each power supply can be directly obtained during the durability test or the completion thereof.

[10]

Disclosure of Invention Technical Problem

[11] Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide an integrated process system for power conversion and characteristic test in that the DC output powers of each power supply consumed in the form of thermal energy through a load for durability test is converted into an AC power of 110-220 Vac and the converted Ac power can be recycled so as to perform the durability test, thereby remarkably reducing the electric powers used in the entire manufacturing process.

[12] Another object of the present invention is to provide an integrated process system for power conversion and characteristic test having a DC- AC converting portion capable of recycling the DC output power as the AC input power for durability test.

[13] Further another object of the present invention is to provide an integrated process system for power conversion and characteristic test in that the DC output powers outputted from each power supply in course of the durability test can be obtained through a current sensor at a predetermined interval (capable of fixing according to the condition of the power supply), so that the information on the quality of each power supply can be directly obtained during the durability test or the completion thereof, thereby removing characteristic obtaining process for confirming the quality of each power supply of finishing the durability test.

[14] Technical Solution

[15] To accomplish the objects, the present invention provides an integrated process system for power conversion and characteristic test comprising: an input portion for unifying DC output powers of a plurality of power supplies electrically connected to each other in a row, transmitting the unified DC output powers to a DC- AC converting portion, transmitting the obtained values of the DC output powers to a controller, and allowing the output powers of the plurality of power supplies to be regularly outputted; the DC- AC converting portion for converting the unified DC output powers of the power supplies received from the input portion into AC input powers of 110~220Vac; a current sensor for obtaining the total value of the AC input powers converted through the DC- AC converting portion and transmitting it to the controller; and the controller for controlling the input portion so as to regularly maintain the DC output powers of each power supply, controlling the DC- AC converting portion as to convert the DC into the AC, and supplying a short AC input power through an external AC power supply of 110~220Vac.

[16] Preferably, the input portion comprises; other current sensors for obtaining the values of the AC input powers of each power supply; an ADC (Analog To Digital Converter) for periodically sampling the values of the DC output powers received from the current sensors and transmitting them to the controller; a communication portion for transmitting the sampled values of the DC output powers of each power supply received from the ADC (Analog To Digital Converter) to the controller; and a current controller for receiving a control signal from the controller and adjusting the DC output power values.

[17] Preferably, the input portion comprises; other current sensors for obtaining the values of the AC input powers of each power supply; an ADC (Analog To Digital Converter) for periodically sampling the values of the DC output powers received from the current sensors and transmitting them to the controller; a communication portion for transmitting the sampled values of the DC output powers of each power supply received from the ADC (Analog To Digital Converter) to the controller; a switching portion for reducing a quantity of the current sensors; and a current controller for receiving a control signal from the controller and adjusting the DC output power values.

[18] Preferably, the DC-AC converting portion serves to convert the unified DC output powers, which are different from each other, received from a plurality of the input portions into AC input powers and combing the converted AC input powers with the AC input power supplied from the external AC power supply of 110-220 Vac so as to output an entire AC input power necessary to a durability test. [19] Preferably, the controller stores the DC output power values of the plurality power supplies electrically connected to each other in a row and transmit the stored values to outside through a serial type, an ETHERNET, a USB memory, a wireless communication so as to decrease a process time of the characteristic test of the power supply in which the durability test process is completed.

[20] To accomplish the objects, the present invention provides an integrated process system for power conversion and characteristic test comprising: a switching portion for allowing output terminals of each power supply to be electrically connected to a load variation portion and a output sensing portion in course of the durability test and allowing the output terminals to be electrically connected to an externally variable power supply in a measuring process of the over voltage protection; the load variation portion for varying each load of the output terminals according to the control of the controller for measuring the over voltage protection, over current protection, and load variation test; output sensing portion for receiving voltage and current outputs of each power supply in course of the characteristic test in predetermined period and step; an ADC (Analog To Digital Converter) for periodically sampling the voltage and current outputs received from the output sensing portion and transmitting them to a CPU; the CPU for receiving the sampled voltage and current output values, controlling a current controller, transmitting them to a controller, waiting for the following order transmittance, and controlling boosting and reducing range of a boosting portion according to a control of the controller; a communication portion for taking charge of a communication of the CPU and the controller; a current controller for controlling the outputs of each power supply according to an order of the CPU; a boosting portion for performing boosting or reducing step so as to convert each DC or AC output power of the power supplies classified into a low, middle, or high pressure into an AC of 110~220Vac; an input portion for integrating the outputs of each power supply converted equally in the boosting portion by boosting or reducing the DC output powers, which are different from each other, into one DC output power; and an externally variable power supply for performing an over voltage protection function of each power supply.

[21] Preferably, the integrated process system for power conversion and characteristic test further comprises: a write medium for gradually controlling a load variation portion, an output sensing portion, and the boosting portion in the CPU according to an order of the controller; and another write medium for directly controlling the function of the CPU in a GUI (Graphic User Interface).

[22] Preferably, the externally variable power supply is connected to the switching portion through an attaching and deattaching manner or a parallel connection manner and an oscilloscope, a multi-meter, or a special function module (function generator etc.) are freely added thereto so as to further perform a measurement of a tern-on time (time required to reach a rated voltage from the output voltage of each power supply after applying the input power to the power supply), a measurement of a tern-off time (time required to reach a zero output voltage of the power supply after removing the power applied to the power supply), or an output signal test on a special input signal (control signal), in addition to a measurement of an output voltage/current stability, an over current protection test, an over voltage protection test, a load variation test, and a measurement of a ripple voltage.

[23] Preferably, each element of the input portion is provided with separate test point terminals so as to periodically test and correct the soundness of each element thereof.

[24] Preferably, each element of the input portion for characteristic test is directly controlled through the controller so as to add and delete the items of the characteristic test or change an operation order and initial values of each element thereof.

[25] Preferably, the output voltage/current of the power supply obtained from the output sensing portion is sampled at a sampling rate of several KHz ~ dozens of Hz and the ripple voltage values are automatically sampled at a sampling rate of dozens of KHz ~ dozens of MHz through the ADC in course of the durability test.

[26] To accomplish the objects, the present invention provides an integrated process method for power conversion and characteristic test comprising steps of: converting different DC or Ac output powers of a plurality of power supplies into optimum AC input powers through a boosting or a reducing thereof; integrating the boosted or reduced DC or Ac output powers into one output; and converting the integrated DC or Ac output powers into AC 110~220Vac, AC 380Vac or AC 380Vac used in a general or industrial settings, whereby being recycled as input powers of AC 110~220Vac, AC 380Vac or AC 380Vac used in a general or industrial settings for durability test thereof.

[27] Preferably, the method further comprises steps of; sensing each DC output power of the plurality of power supplies electrically connected to each other in a row and transmitting them to a CPU through an ADC (Analog To Digital Converter); transmitting the values of DC or AC output powers of the power supplies received from the CPU to a controller through a communication portion; and allowing DC output powers of all power supply to be regularly outputted on the basis of a predetermined value by controlling the current controller through the controller.

[28] Preferably, the method further comprises steps of: supplying a necessary AC input power of 110-220 Vac to each power supply through the external 110-220 Vac power supply by calculating the difference between the AC input power provided to the power supply in course of the durability test and the AC power converted through DC- AC converting portion. [29] Preferably, the boosting or reducing step comprises steps of: classifying various kinds of outputs of each power supply in course of the durability test into a low, middle, or high pressure; transmitting the outputs of each power supply classified into the low, middle, or high pressure to an independent input portion; and integrating the different outputs of each power supply so as to be outputted equally through the boosting or reducing and collectively converting the integrated outputs into an AC power.

[30] Preferably, in case of the power supply of at least 500 Vac, l,000Vac is reduced to

500Vac and again reduced to 220V ac and then, converted into 110~220Vac in the reducing step.

[31] Preferably, in case of the power supply of at most 50 Vdc, 24Vdc is gradually boosted to 50Vdc, 100 Vdc, and 340-380 Vdc and then, gradually converted into 220Vac and 110~220Vac in the boosting step.

[32] Preferably, the method further comprises step of: transmitting the values of DC or

AC output powers (100%, 70%, 50%, etc.) of the power supplies in course of the durability test to the CPU from the controller through a communication portion; varying and testing the DC or AC output powers of each power supply by controlling the current controller by means of the CPU; sensing the varied values of the DC or AC output powers and transmitting them to the CPU through the current sensing portion so as to confirm as to whether the values of the DC or AC output powers are exactly varied or not; and transmitting the results of the varied DC or AC output powers to the controller through the communication portion.

[33] To accomplish the objects, the present invention provides an integrated process method for power conversion and characteristic test comprising steps of: measuring an output voltage/current stability for measuring as to whether the outputs of each power supply firmly maintains the predetermined value or not by varying the AC input powers (220 Vac or 110 Vac for driving the power supply within a fixed range (180Vac-250Vac or 90Vac-130Vac); inducing the outputs of the power supplies so as to gradually increase currents of an abnormal rated current from the power supplies through a load variation portion and measuring a current losing a function of the power supply, thereby comparing the received over current value with a fixed value within a permissible range; inducing the outputs of the power supplies so as to gradually increase voltages of an abnormal rated voltage from the power supplies through a load variation portion and measuring a current losing a function of the power supply, thereby comparing the received over voltage value with a fixed value within a permissible range; controlling a switching portion according to an order of a controller so as to electrically connect plus and minus terminals of output terminals of each power supply to minus and plus terminal of an externally variable power supply re- spectively and applying powers of an opposed polarity to the output terminals of each power supply through the externally variable power supply, thereby inspecting as to whether the function of the power supply is lost; varying arbitrary output conditions (100%, 70%, and 50%, unloading) of each power supply through the load variation portion, thereby inspecting as to whether the outputs of each power supply regularly maintains the predetermined value or not; and measuring a ripple voltage mixed in the output power of each power supply.

[34] Preferably, the externally variable power supply is connected to the switching portion through an attaching and deattaching manner or a parallel connection manner and an oscilloscope, a multi-meter, or a special function module (function generator etc.) are freely added thereto so as to additionally perform a measurement of characteristic test items besides common test, and each element (load variation portion, output sensing portion, ACD, current controller, CPU, communication portion, boosting portion, output integrating portion, controller, DC- AC converting portion) of power conversion system is provided with separate test point terminals.

[35] Preferably, the method further comprises steps of: reducing the number of controlling input portion through the controller in case of power supplies having large capacity and various kinds of outputs or increasing the number of controlling input portion through one controller in case of power supplies having small capacity and two or three outputs; and dividing each controller into various combination so as to dis- persively control each power supply, thereby stably performing the characteristic test of the plurality of power supplies.

[36]

Advantageous Effects

[37] In the integrated process system for power conversion and characteristic test there are effects in that the DC output powers of each power supply consumed in the form of thermal energy through a load for durability test is converted into the AC power of 110-220 Vac and the converted Ac power can be recycled so as to perform the durability test, thereby remarkably reducing the electric powers used in the entire manufacturing process.

[38] Also, there is another effect in that the durability test and the characteristic test can be performed at the same time, thereby reducing the entire manufacturing process.

[39] Also, there is another effect in that the DC output powers outputted from each power supply in course of the durability test can be obtained through a current sensor at a predetermined interval (capable of fixing according to the condition of the power supply), so that the information on the quality of each power supply can be directly obtained during the durability test or the completion thereof, thereby removing char- acteristic obtaining process for confirming the quality of each power supply of finishing the durability test. [40]

Brief Description of the Drawings

[41] The above as well as the other objects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: [42] FIG. 1 is a schematic block diagram illustrating a conventional durability tester of the power supply used in a manufacturing process of the power supply; [43] FIG. 2 is a schematic block diagram illustrating a durability tester having a power converter according to the present invention for recycling the electric power wasted and emitted in the form of the thermal energy through the load during the durability test; [44] FIG. 3 is a schematic block diagram illustrating the input portion of the power converter according to the present invention; [45] FIG. 4 is a schematic block diagram illustrating the input portion of the power converter having a switching portion for reducing the quantity of the current sensors according to another embodiment of the present invention; [46] FIG. 5 is a schematic block diagram illustrating the input portion of the power converter having a load variation portion, an output sensing portion, a boosting portion, an output integrating portion, an externally variable power supply, and a switching portion for combing the durability test process with the characteristic test process of the power supply according to further another embodiment of the present invention; [47] FIG. 6 is a schematic flow chart illustrating a durability test using the power converter according to the present invention; [48] FIG. 7 is a schematic flow chart illustrating a process of the input portion of the power converter for automatically combing the power conversion process with the characteristic test process of the power supply; and [49] FIG. 8 is a schematic flow chart illustrating a process of the input portion having the switching portion of the power converter for automatically combing the power conversion process with the characteristic test process of the power supply. [50]

Best Mode for Carrying Out the Invention [51] A preferred embodiment of the invention will be described in detail below with reference to the accompanying drawings. [52] An integrated process system for power conversion and characteristic test according to the present invention includes a DC- AC converting portion 215 for converting a DC output power (Vdc) of the power supply 105 into an AC input power of 110-220 Vac used in a durability test of the power supply, a current sensor 226 for sensing the AC power of 110~220Vac converted in the DC- AC converting portion 215, a controller 210 for comparing the AC power of 110~220Vac sensed in the current sensor 226 with a predetermined total AC input power during the durability test and supplying a short AC input power from an external AC power supply 225 of 110~220Vac, and an input portion 205 for allowing DC output powers of all power supply 105 to be regularly outputted at all times by controlling the current sensor 226 for sensing each output of the power supplies 105 in course of the durability test and each output of the power supplies 105 on the basis of the sensed current values so as to stabilize each output of all power supply 105 according to an electrical parallel connection of each power supply 105 during the durability test.

[53] Here, the present invention relates to the integrated process system and method thereof in that the high-power resistance is changed to the DC- AC converting portion 215 in order to prevent a waste of electric power generated from the emission of thermal energy owing to the use of the high-power resistance as a load 110 during an essential durability test of the power supply (confirmation test of output stability for about 4 consecutive times after the load is applied to the power supply), so that the DC output power (Vdc) produced in the power supply 105 is again converted into the AC power of the power supply 105 during the durability test and it can be utilized as the AC input power of the power supply 105 for performing the durability test, thereby remarkably decreasing the quantity of electricity consumed in the durability test.

[54] FIG. 1 is a schematic block diagram illustrating a conventional durability tester 100 of the power supply.

[55] Generally, the durability test of about 500-3,000 power supplies can be performed at the same time so as to decrease the period of production and lower the manufacturing cost. However, a plenty of electric powers is required in order to perform the durability test of several hundred power supplies at one time. Accordingly, the bulk of the electric powers are consumed in the durability test among the manufacturing processes of the power supply 105, thereby highly increasing the manufacturing cost thereof.

[56] A process of the durability test of the power supply will be described below.

[57] Firstly, the assembled power supply 105 is mounted to the durability tester and then, the general electric power 115 of 110~220Vac is applied to the power supply 105 for driving the power supply 105.

[58] In the power supply 105, a rated DC output power is emitted to the load 110 for at least 4 consecutive times. Then, in the load 100, the DC output power is consumed as a heat, so that the rated output is continuously emitted from the power supply 105. [59] As described above, since the rated DC output power of the power supply 105 is consumed as a thermal energy through the load 110 during the durability test, a plenty of electric power is wasted. [60] FIG. 2 is a schematic block diagram illustrating a durability tester having a power converter 200 according to the present invention for recycling the electric power wasted and emitted in the form of the thermal energy through the load 110 during the durability test. [61] As shown, in the durability test of the power supply, the electric power 115 of

110~220Vac is applied to the power supply 105, so that the power supply 105 is driven. Also, the rated DC output power is emitted to the load 110 in the power supply

105. Then, the DC output power is continuously emitted to the air in the form of thermal energy in the load 100, so that the rated DC output power can be continuously emitted from the power supply 105. [62] Accordingly, the present invention relates to the integrated process system and method thereof in that the rated DC output power of the power supply 105 wasted and emitted to the air in the form of the thermal energy through the load 110 can be recycled, thereby remarkably decreasing the waste of the electric power and the entire electric power used in the whole durability test can be remarkably reduced, thereby lowering the manufacturing cost. [63] Here, the power supply 105 can supply a single DC output power or various DC output powers. [64] Also, a single DC output power supply and a multiple DC output power supply (2 through 5 kinds) can be applied to the present invention all together. [65] In the meantime, the power supply 105 for supplying two kinds of DC output powers is shown in FIG. 2 for the sake of convenience of explanation. Also, all kind of power converts (power supply, inverter and so on) can be applied. The present invention is not limited to any kind thereof. [66] Here, each DC output power of the power supply 105 for the durability test is electrically connected to the input portion 205 of the power converter 200 according to the present invention. [67] As shown in FIG. 2, in case of the power supply 105 for supplying two kinds of DC output powers, the input portion 205 of the power converter 200 includes two kinds.

That is, the number of to the input portion 205 (input portion A, input portion B...) of the power converter 200 can be determined according to the kind of the DC output power of the power supply 105 for the durability test. [68] The same outputs Al, A2,..., An or Bl, B2,..., Bn as the power supplies 105 are electrically connected to the same input portions 205 (input portion A or input portion B) and then, the rated AC output power is supplied to the power supply 105, thereby starting the durability test.

[69] The input portion 205 serves to obtain each DC output power outputted from power supplies 105 at intervals of regular time through the current sensor 226 in course of the durability test and transmit them to the controller 210. Also, the controller 210 serves to compare the DC output power values of each power supply 105 with a predetermined DC output power value. Here, the controller 210 serves to control current controller 227 of the input portion 205 in order to continually output the same DC output power from a plurality power supplies 150, which is electrically connected to each other in a row.

[70] The controller 210 serves to transmit the DC output powers of each power supply

105, which is regularly controlled in the input portion 205, to the DC- AC converting portion 215. The DC- AC converting portion 215 serves to convert the received DC output power (Vdc) into the AC input power of 110~220Vac.

[71] Also, the current sensor A (220) serves to obtain the value of the AC power of

110-220 Vac converted in the DC- AC converting portion 215 and the controller 210 serves to calculate the difference between AC powers provided to the power supply 105 in course of the durability test and supply the necessary AC input power of 110-220 Vac to each power supply 105 through the external AC power supply 225.

[72] In order to shorten the process time of the characteristic test (stability criterion test of DC output power) of the power supply 105, in which the durability test is completed, the controller 210 serves to store the DC output power values of the plurality power supplies 150, which is electrically connected to each other in a row, and transmit the stored values to outside through an online or offline and so on.

[73] The durability tester according to the present invention as shown in FIG. 2 can include at least one server (or device) having at least one functional element (for example, power convert and so on). Also, it can be embodied through at least one computer program written in a write medium provided in a predetermined server (or device).

[74] FIG. 3 is a schematic block diagram illustrating the input portion 205 of the power converter 200 according to the present invention.

[75] In case of the same power supplies, which are electrically connected to each other in a row, there is some difference between them in terms of DC output power. That is, in case of the power supply having a comparatively high DC output power, the output is occurred. Meanwhile, in case of the power supply having a comparatively low DC output power, it cannot be operated.

[76] In order to solve the problems, each output of all power supplies 105 for performing the durability test is electrically connected to the input portion 205 through the current controller 227 and the current sensor 226. That is, the input portion 205 includes a current sensor 225 for periodically obtaining values of the DC output power of a plurality of power supplies, which is electrically connected to each other in a row, during a certain period of time and transmit them to a ADC (Analog To Digital Converter) 228, the ADC (Analog To Digital Converter) 228 for periodically sampling the values of the DC output power received from the current sensor 225 and transmitting them to a communication portion 229, and the communication portion 229 for transmitting the sampled values of the DC output power of the plurality of power supplies received from the ADC (Analog To Digital Converter) 228 to the controller 210. The controller 210 serves to compare the DC output power values of each power s upply 105 received from the communication portion 229 with a predetermined DC output power value and control current controller 227 of the input portion 205 to be regularly outputted at all times.

[77] Each DC output power of each power supply 105 stabilized through the current sensor 226, the ADC (Analog To Digital Converter) 228, the controller 210, the communication portion 229, and the current controller 226 is transmitted to the DC- AC converting portion 215 through a DC output 230.

[78] FIG. 4 is a schematic block diagram illustrating the input portion 205-1 of the power converter 200 having a switching portion 231 for reducing the quantity of the current sensors 226 according to another embodiment of the present invention.

[79] As shown in FIG. 4, each output (output 1, output 2,..., output n) of all power supplies 105 is electrically connected to the switching portion 231 through the current controller 227. Also, each output (output 1, output 2,..., output n) of all power supplies 105 connected to the switching portion 231 is usually connected to the DC output portion 230 , so that each DC output power of a plurality of power supplies 105 are continually supplied to the DC- AC converting portion 215. Moreover, each DC output power of a plurality of power supplies 105 are periodically and gradually switched one by one through the switching portion 231 and the switched DC output power is periodically connected to the DC output 230 through the current sensor 226 one by one. Accordingly, each DC output power value of the power supplies 105 are periodically and gradually transmitted to the controller 210 one by one through the ADC (Analog To Digital Converter) 228 and the communication portion 229.

[80] The input portion according to the present invention as shown in FIG. 4 can include at least one server (or device) having at least one functional element (for example, switching portion and so on). Also, it can be embodied through at least one computer program written in a write medium provided in a predetermined server (or device).

[81] FIG. 5 is a schematic block diagram illustrating the input portion 205-2 of the power converter 200 having a load variation portion, an output sensing portion, a boosting portion, an output integrating portion, an externally variable power supply, and a switching portion for combing the durability test process with the characteristic test process of the power supply according to further another embodiment of the present invention.

[82] In case of the durability test process of the power supply 105, the output sensing portions 234 sense the outputs (values necessary to judge the good and bad of product, currents, voltages, ripple values and so on) and transmit the sensed values to a CPU 231 through the ADC (Analog To Digital Converter) 228. Also, the CPU 231 serves to control the current controller 227 on the basis of the output values (currents, voltages, ripple values and so on) received from the output sensing portions 234 so as to regularly maintain the outputs of the plurality of power supplies 105.

[83] Also, the CPU 231 serves to control the boosting portion 223 for equally boosting various DC output power values so as to effectively convert various kinds of the DC output powers of the power supplies 105 into the AC input power of 110-220 Vac at the same time.

[84] The various DC output power values boosted equally in the boosting portion 223 are integrated into one DC output power in the output integrating portion 235 and then, it is transmitted to the DC- AC converting portion 215.

[85] In order to test the power supply through the variance of the DC output power thereof, when the DC output power values of the power supply 105 are transmitted to the CPU 231 through the communication portion 229 in the controller 210, the CPU 231 controls the current controller 227, so that the DC output power values of the power supply 105 in course of the durability test can be varied. Continuously, the varied result is again inspected through the output sensing portion 234 and then, the variance thereof is completed, so that the result on the completed variance is transmitted to the controller 210 through the communication portion 229.

[86] Also, the parameters (values for discriminating between good and bad of the products) obtained in the existed characteristic test process of the power supply are unified as follows without transferring the products to the conventional characteristic test process. Here, the characteristic test process includes a measurement of an output voltage/current stability according to the variation of an AC input), an over current protection (a measurement of a current losing the function of the power supply owing to the output of an abnormal rated current), an over voltage protection (a measurement of a voltage losing the function of the power supply owing to the output of an abnormal rated voltage), a measurement of a ripple voltage (an ingredient of an AC voltage output contained in a DC output voltage of a DC power supply and an important parameter capable of determining a quality of the power supply; the smaller, the better). [87] In the measuring step of the output voltage/current stability for measuring as to whether the stable output is generated from the power supply owing to the unstable AC input power, the DC- AC converting portion 215 serves to supply the varying AC input powers to the corresponding power supply 105 on the basis of predetermined fixing values thereof (for example, an AC input power of 200Vac or 250Vac is supplied to the power supply operated in AC 220Vac so as to confirm as to whether the rated output is generated from the power supply or not). Also, the outputting values of the power supply, which receives the varied AC input power from the DC- AC converting portion 215, are transmitted to the controller 210 via the ADC (Analog To Digital Converter) 228 and the communication portion 229 to be utilized as a judging parameter of the good and bad thereof, thereby judging the stability of the outputs of the power supply on the variation of the AC input power.

[88] In the measuring step of the over current protection (a measurement of a current losing the function of the power supply owing to the output of an abnormal rated current), the fixed selective output current variation values of the sort of the power supplies are transmitted to the CPU 231 through the communication portion 229 by means of the user and the CPU 231 controls the load variation portion 232 so as to induce the output of the abnormal rated current, thereby detecting the over current of losing the function of the power supply and transmitting it to the controller 210. The controller 210 serves to compare the received over current value with the fixed value within a permissible range and judge the good and bad of the power supply.

[89] In the measurement test of the over voltage protection (a measurement of a voltage losing the function of the power supply owing to the output of an abnormal rated voltage), the CPU 231 of the controller allows the output terminals of the power supplies 105 to be electrically connected to the externally variable power supply 236 through the switching portion 237. In this manner, the controller 210 controls the externally variable power supply 236, so that the supply of the DC power applied to the externally variable power supply 236 is gradually increased, thereby obtaining the over voltage value of losing the function thereof. The controller 210 serves to compare the received over voltage value with the fixed value within a permissible range and judge the good and bad of the power supply. Also, in the measurement test of the over voltage protection, instead of the externally variable power supply 236, the load variation portion 232 can serve to gradually increase the supply of the DC power applied to the externally variable power supply 236. In the measurement test of the ripple voltage, since the ripple voltage itself has a high-frequency, there is a problem in that it should be sampled at high speed.

[90] The ripple voltage value obtained from the output sensing portion 234 is sampled at a predetermined sampling rate (a number of obtained data per second) through an ADC 228 and the obtained value is transmitted to the controller 210. Here, the sampling rate can be arbitrary varied in the controller as occasion demands. [91] Also, the controller 210 controls the load variation portion 232 through the CPU

231. In the durability test, the output condition of the power supply can be freely controlled like 100%, 80%, and 70% and so forth. [92] The load variation portion 232 can control the output surrounding of the power supply during the durability test. [93] The input portion according to the present invention as shown in FIG. 5 can include at least one server (or device) having at least one functional element (for example, load variation portion, output sensing portion, boosting portion, output integrating portion, externally variable power supply, and switching portion and so on). Also, it can be embodied through at least one computer program written in a write medium provided in a predetermined server (or device). [94] FIG. 6 is a schematic flow chart illustrating a durability test using the power converter 200 according to the present invention. [95] Firstly, it checks out the quantity of the power supplies 105 and the output number thereof (305) and it can settle the number of the input portions of the power converter

200 (310). [96] The outputs of the power supplies 105 are electrically connected to the input portions of the power converter 200 (315). [97] The DC output power (Vdc) of the power supply 105 outputted through the supply of the rated AC input power of 110~220Vac is transmitted to the DC- AC converting portion 215 (325). [98] Here, the controller 210 serves to accord each DC output power of all power supply

105 with the fixed value without an error, thereby confirming the stability of output of each power supply electrically connected to each other in a row (330). [99] The DC- AC converting portion 215 serves to convert the DC output power (Vdc) of the power supply 105 into the AC input power (335). [100] The current sensor A (220) serves to calculate the total amount of the AC input power converted in the DC- AC converting portion 215 (340). [101] The controller 210 serves to calculate the difference between AC powers provided to each power supply 105 in course of the durability test and supply the necessary AC input power of 110-220 Vac to each power supply 105 through the external AC power supply 225 (345). [102] Also, the controller 210 serves to generate the AC input power necessary to the durability test and continually supply the generated AC input power to each power supply 105 in course of the durability test (320). [103] Finally, the controller 210 serves to compare the durability test time with the fixed test time. Here, if the test time thereof is shorter than the fixed time, the durability test is continually performed (350). Meanwhile, if the test time thereof is longer than the fixed time, the durability test is completed (360).

[104] FIG. 7 is a schematic flow chart illustrating a process of the input portion 205-2 of the power converter for automatically combing the power conversion process with the characteristic test process of the power supply.

[105] Firstly, the DC output powers of each power supply are outputted in the durability test (405).

[106] The current sensor 226 obtains each DC output power and the obtained values are transmitted to the ADC (Analog To Digital Converter) 228 (410).

[107] The ADC (Analog To Digital Converter) 228 serves to periodically sample the values of the DC output power received from the current sensor 226 and transmit them to the controller 210 through the communication portion 229 (420).

[108] Finally, the controller 210 serves to compare the DC output power values of each power supply 105 received from the communication portion 229 with the predetermined DC output power value (425). Here, if the compared values are identically with each other (430), the DC output power values are again obtained and the above process is repeatedly and periodically performed. Meanwhile, if the compared values are not identically with each other (435), the controller 210 allows the control current controller 227 to be controlled through the communication portion 229, thereby each DC output power of the power supplies 105 can be regularly outputted at all times (440).

[109] FIG. 8 is a schematic flow chart illustrating a process of the input portion 205 having the switching portion 231 of the power converter for automatically combing the power conversion process with the characteristic test process of the power supply.

[110] Firstly, the DC output powers of each power supply are outputted in the durability test (405).

[I l l] The DC output powers of each power supply are integrated through the DC output

230 and the integrated power is transmitted to the DC- AC converting portion 215 (410).

[112] Here, the switching portion 231 serves to switch each DC output power terminal of the power supplies, so that each DC output power terminal gradually selected according to predetermined order and period loses electrical contact with the DC output 230 one by one, thereby automatically connecting to the current sensor 226 (415).

[113] The current sensor 226 obtains each DC output power and the obtained values are transmitted to the ADC (Analog To Digital Converter) 228 (420).

[114] The ADC (Analog To Digital Converter) 228 serves to periodically sample the values of the DC output power received from the current sensor 226 and transmit them to the controller 210 through the communication portion 229 (430).

[115] Finally, the controller 210 serves to compare the DC output power values of each power supply 105 received from the communication portion 229 with the predetermined DC output power value (525). Here, if the compared values are identically with each other (430), the DC output power values are again obtained and the above process is repeatedly and periodically performed. Meanwhile, if the compared values are not identically with each other (435), the controller 210 allows the control current controller 227 to be controlled through the communication portion 229, thereby each DC output power of the power supplies 105 can be regularly outputted at all times (450).

[116] While this invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments and the drawings, but, on the contrary, it is intended to cover various modifications and variations within the spirit and scope of the appended claims.

[117]

Industrial Applicability

[118] The present invention relates to an integrated process system for power conversion and characteristic test in that the electric powers can be recycled and cut down in a durability test and the durability test and the characteristic test for confirming the quality of each power supply can be performed at the same time, thereby reducing the entire manufacturing process.

Claims

[1] An integrated process system for power conversion and characteristic test comprising: an input portion for unifying DC output powers of a plurality of power supplies electrically connected to each other in a row, transmitting the unified DC output powers to a DC-AC converting portion, transmitting the obtained values of the DC output powers to a controller, and allowing the output powers of the plurality of power supplies to be regularly outputted; the DC- AC converting portion for converting the unified DC output powers of the power supplies received from the input portion into AC input powers of 110~220Vac; a current sensor for obtaining the total value of the AC input powers converted through the DC- AC converting portion and transmitting it to the controller; and the controller for controlling the input portion so as to regularly maintain the DC output powers of each power supply, controlling the DC- AC converting portion as to convert the DC into the AC, and supplying a short AC input power through an external AC power supply of 110~220Vac.

[2] An integrated process system for power conversion and characteristic test as set forth in claim 1, wherein the input portion comprises; other current sensors for obtaining the values of the AC input powers of each power supply; an ADC (Analog To Digital Conversion) for periodically sampling the values of the DC output powers received from the current sensors and transmitting them to the controller; a communication portion for transmitting the sampled values of the DC output powers of each power supply received from the ADC (Analog To Digital Conv ersion) to the controller; and a current controller for receiving a control signal from the controller and adjusting the DC output power values.

[3] An integrated process system for power conversion and characteristic test as set forth in claim 1, wherein the input portion comprises; other current sensors for obtaining the values of the AC input powers of each power supply; an ADC (Analog To Digital Conversion) for periodically sampling the values of the DC output powers received from the current sensors and transmitting them to the controller; a communication portion for transmitting the sampled values of the DC output powers of each power supply received from the ADC (Analog To Digital Conversion) to the controller; a switching portion for reducing a quantity of the current sensors; and a current controller for receiving a control signal from the controller and adjusting the DC output power values.

[4] An integrated process system for power conversion and characteristic test as set forth in claim 1, wherein the DC- AC converting portion serves to convert the unified DC output powers, which are different from each other, received from a plurality of the input portions into AC input powers and combing the converted AC input powers with the AC input power supplied from the external AC power supply of 110~220Vac so as to output an entire AC input power necessary to a durability test.

[5] An integrated process system for power conversion and characteristic test as set forth in claim 1, wherein the controller stores the DC output power values of the plurality power supplies electrically connected to each other in a row and transmit the stored values to outside through a serial type, an ETHERNET, a USB memory, a wireless communication so as to decrease a process time of the characteristic test of the power supply in which the durability test process is completed.

[6] An integrated process system for power conversion and characteristic test comprising: a switching portion for allowing output terminals of each power supply to be electrically connected to a load variation portion and an output sensing portion in course of the durability test and allowing the output terminals to be electrically connected to an externally variable power supply in a measuring process of the over voltage protection; the load variation portion for varying each load of the output terminals according to the control of the controller for measuring the over voltage protection, over current protection, and load variation test; output sensing portion for receiving voltage and current outputs of each power supply in course of the characteristic test in predetermined period and step; an ADC (Analog To Digital Converter) for periodically sampling the voltage and current outputs received from the output sensing portion and transmitting them to a CPU; the CPU for receiving the sampled voltage and current output values, controlling a current controller, transmitting them to a controller, waiting for the following order transmittance, and controlling boosting and reducing range of a boosting portion according to a control of the controller; a communication portion for taking charge of a communication of the CPU and the controller; a current controller for controlling the outputs of each power supply according to an order of the CPU; a boosting portion for performing boosting or reducing step so as to convert each

DC or AC output power of the power supplies into AC input power which is used in course of the above power supplies's durability test; an input portion for integrating the outputs of each power supply converted equally in the boosting portion by boosting or reducing the DC output powers, which are different from each other, into one DC output power; and an externally variable power supply for performing an over voltage protection function of each power supply.

[7] An integrated process system for power conversion and characteristic test as set forth in claim 6, comprising: the CPU controlling a load variation portion, an output sensing portion, and the boosting portion in according to an order of the controller; and in a GUI (Graphic User Interface), controlling the function of the CPU as the same.

[8] An integrated process system for power conversion and characteristic test as set forth in claim 6, wherein the externally variable power supply is connected to the switching portion through an attaching and deattaching manner or a parallel connection manner and an oscilloscope, a multi-meter, or a special function module (function generator etc.) are freely added thereto so as to further perform a measurement of a turn-on time (time required to reach a rated voltage from the output voltage of each power supply after applying the input power to the power supply), a measurement of a turn-off time (time required to reach a zero output voltage of the power supply after removing the power applied to the power supply), or an output signal test on a special input signal (control signal), in addition to a measurement of an output voltage/current stability, an over current protection test, an over voltage protection test, a load variation test, and a measurement of a ripple voltage.

[9] An integrated process system for power conversion and characteristic test as set forth in claim 6, wherein each element of the input portion is provided with separate test point terminals so as to periodically test and correct the soundness of each element thereof.

[10] An integrated process system for power conversion and characteristic test as set f orth in claim 6, wherein a load variation portion, an output sensing portion, the boosting portion, the CPU and a communication portion for characteristic test is directly controlled through the GUI (Graphic User Interface) in the controller so as to add and delete the items of the characteristic test or change an operation order and initial values of each element thereof.

[11] An integrated process system for power conversion and characteristic test as set forth in claim 6, the ADC having a different sampling period per each process

,wherein the output voltage/current of the power supply obtained from the output sensing portion is sampled at a designed peroid, transmitted the controller via the

CPU and a communication portion in course of the durability test; and wherein the output voltage/current of the power supply obtained from the output sensing portion is sampled at another designed peroid, transmitted the controller via the CPU and a communication portion in course of the measuring the ripple voltage process.

[12] An integrated process method for power conversion and characteristic test comprising steps of: converting different DC or Ac output powers of a plurality of power supplies into AC input powers used in the durability test through a boosting or a reducing thereof; integrating the boosted or reduced DC or Ac output powers into one output; and converting the integrated DC or Ac output powers into AC input power, whereby being recycled as input powers and setting for durability test thereof.

[13] A method as claimed in claim 12, further comprising steps of; sensing each DC output power of the plurality of power supplies electrically connected to each other in a row and transmitting them to a CPU through an ADC (Analog To Digital Conversion); transmitting the values of DC or AC output powers of the power supplies received from the CPU to a controller through a communication portion; and allowing DC output powers of all power supply to be regularly outputted on the basis of a predetermined value by controlling the current controller through the controller.

[14] A method as claimed in claim 12, further comprising steps of: converting the DC or Ac output powers of power supply into AC input power for durability test; conjugating the input power from converting step with a input AC power by external power supply in the face of altitude and phase; and suppling-and-demading(connecting) with the conjugated input power and the external power supply in course of the durability test.

[15] A method as claimed in claim 12, wherein the process of converting the DC or

Ac output powers of power supply into AC input power for durability test comprises steps of: classifying various kinds of outputs of each power supply in course of the durability test into a low(0~50V), middle(51~120V), or high(over 121V) pressure; transmitting the outputs of each power supply classified into the Ia low(0~50V), middle(51~120V), or high(over 121V) pressure to an independent input portion; and integrating the different outputs of each power supply so as to be outputted equally through the boosting or reducing and collectively converting the integrated outputs into an AC power.

[16] A method as claimed in claim 12, wherein, in case of the power supply of at 500

Vac or 1000 Vac over, below 500 Vac is reduced to 220Vac(or 1 lOVac) by one- step and over l,000Vac is primarily reduced to 500Vac and again reduced to 220 Vac (or 110 Vac) in the reducing step.

[17] A method as claimed in claim 12, wherein, in case of the power supply of at most 50 V, below 50 Vdc is primarily boosted to a middle(51~120Vdc) voltage pressure, again boosted to 380Vdc and converted into a AC input power; below 50 Vac is primarily boosted to a middle(51~120Vac) voltage pressure, again boosted to 220Vac or 380Vac or 440Vac in the boosting step.

[18] A method as claimed in claim 12, further comprising step of: transmitting the values of DC or AC output powers of the power supplies in course of the durability test to the CPU from the controller through a communication portion; varying and testing the DC or AC output powers of each power supply by controlling the current controller by means of the CPU; sensing the varied values of the DC or AC output powers and transmitting them to the CPU through the current sensing portion so as to confirm as to whether the values of the DC or AC output powers are exactly varied or not; and transmitting the results of the varied DC or AC output powers to the controller through the communication portion.

[19] An integrated process method for power conversion and characteristic test comprising steps of: measuring an output voltage/current stability for measuring as to whether the outputs of each power supply firmly maintains the predetermined value or not by varying the AC input powers for driving the power supply within a fixed range; varying the outputs of the power supplies so as to gradually increase currents of an abnormal rated current from the power supplies through a load variation portion and measuring a current losing a function of the power supply, thereby comparing the received over current value with a fixed value within a permissible range; varying the outputs of the power supplies so as to gradually increase voltages of an abnormal rated voltage from the power supplies through a load variation portion and measuring a current losing a function of the power supply, thereby comparing the received over voltage value with a fixed value within a permissible range; controlling a switching portion according to an order of a controller so as to electrically connect plus and minus terminals of output terminals of each power supply to minus and plus terminal of an externally variable power supply respectively and applying powers of an opposed polarity to the output terminals of each power supply through the externally variable power supply, thereby inspecting as to whether the function of the power supply is lost; varying arbitrary output conditions of each power supply through the load variation portion, thereby inspecting as to whether the outputs of each power supply regularly maintains the predetermined value or not; and measuring a ripple voltage mixed in the output power of each power supply.

[20] A method as claimed in claim 19, wherein the externally variable power supply is connected to the switching portion through an attaching and deattaching manner or a parallel connection manner and an oscilloscope, a multi-meter, or a special function module (function generator etc.) are freely added thereto so as to additionally perform a measurement of characteristic test items besides common test, and each element (load variation portion, output sensing portion, ACD, current controller, CPU, communication portion, boosting portion, output integrating portion, controller, DC- AC converting portion) of power conversion system is provided with separate test point terminals.

[21] A method as claimed in claim 19, further comprising steps of: reducing the number of controlling input portion through the controller in case of power supplies having large capacity and various kinds of outputs or increasing the number of controlling input portion through one controller in case of power supplies having small capacity and two or three outputs; and dividing each controller into various combination so as to dispersively control each power supply, thereby stably performing the characteristic test of the plurality of power supplies.