Discharge of overvoltages in a resonant converter

Abstract

The invention relates to a resonant converter comprising a transformer (T) which comprises a primary winding (L6) and a secondary winding (L1, L2), wherein - the secondary winding (L1, L2) is divided into a first secondary winding section (L1) and a second secondary winding section (L2); - the primary winding (L6), the first secondary winding section (L1) and the second secondary winding section (L2) are arranged next to one another on a common limb of a magnetic core of the transformer (T); - the primary winding (L6) is arranged between the first secondary winding section (L1) and the second secondary winding section (L2); - the first secondary winding section (L1) and the second secondary winding section (L2) are each spaced apart from the primary winding (L6) by a distance (a); - the first secondary winding section (L1) and the second secondary winding section (L2) are interconnected in a centre tap circuit; - the first secondary winding section (L1) is connected in series with a first rectifier element (M1) in a first rectifier branch and the second secondary winding section (L2) is connected in series with a second rectifier element (M2) in a second rectifier branch; and - a discharge unit is arranged in the resonant converter and can be used to discharge energy stored in leakage inductances of the secondary winding sections (L1, L2) during a charge reversal of the first rectifier element (M1) and / or the second rectifier element (M2).

Description

[0001] 202413275

[0002] 1

[0003] Dissipation of overvoltages in a resonant transducer

[0004] The invention relates to a resonant converter comprising a transformer.

[0005] Such a resonant converter is used, for example, in switched-mode power supplies and typically generates a DC voltage.

[0006] Resonant converters can incorporate transformers. In such converters, the primary side features an LC resonant circuit, implemented with a resonant capacitor and a resonant inductor. This is disadvantageous because it requires separate components in addition to the transformer.

[0007] Based on the described disadvantages in the prior art, the invention aims to provide an efficient, inexpensive and compact resonant transducer with a long service life and high reliability.

[0008] This task is solved by a resonant converter comprising a transformer which includes a primary winding and a secondary winding, wherein

[0009] - the secondary winding is divided into a first partial secondary winding and a second partial secondary winding;

[0010] - the primary winding, the first partial secondary winding and the second partial secondary winding are arranged side by side on a common leg of a magnetic core of the transformer;

[0011] - the primary winding is arranged between the first partial secondary winding and the second partial secondary winding;

[0012] - the first partial secondary winding and the second partial secondary winding are each spaced a distance away from the primary winding;

[0013] - the first partial secondary winding and the second partial secondary winding are connected in a center-tap circuit;

[0014] - the first partial secondary winding in a first rectifier branch is connected in series with a first rectifier element and the second partial secondary winding in a second rectifier branch is connected in series with a second rectifier element; and

[0015] - a leakage unit is arranged in the resonant converter, through which energy stored in the leakage inductances of the windings during a charging and discharging process of the first rectifier element and / or the second rectifier element can be dissipated. 202413275

[0016] 2

[0017] Dividing the secondary winding into a first and second partial secondary winding, and spacing each of these partial secondary windings from the primary winding, creates a leakage inductance. This inductance acts as a resonant inductance in the resonant converter, replacing the primary inductance. This eliminates the need for a separate component for the resonant inductance. Additionally, the spacing between the windings reduces the induced eddy currents, resulting in less heating of the windings. Furthermore, improved cooling of the windings is achieved if the gap between the windings is not filled.

[0018] By positioning the primary winding between the first and second sub-secondary windings, the distance between the two sub-secondary windings is further increased. This ensures that no unenergized sub-secondary winding is directly exposed to the stray field of an energized sub-secondary winding, thus preventing additional eddy current losses.

[0019] Additionally, the power loss of the secondary windings is distributed over a larger installation space, which allows for improved cooling of the windings.

[0020] By connecting the two secondary windings in a center-tap configuration and connecting the first secondary winding in series with a first rectifier element in a first rectifier branch, and the second secondary winding in series with a second rectifier element in a second rectifier branch, rectifier elements are saved in a particularly advantageous way. This results in lower power loss in the resonant converter. Furthermore, the resonant converter can thus be manufactured more cheaply and compactly.

[0021] By incorporating a leakage unit into the resonant converter, which allows the dissipation of energy stored in the leakage inductances of the partial secondary windings during charging and discharging of the first and / or second rectifier elements, a long service life and high reliability of the resonant converter are ensured. Furthermore, rectifier elements designed for lower reverse voltages can be used. These rectifier elements are less expensive and also exhibit lower power dissipation. In other words, the leakage unit allows the dissipation of energy stored in leakage inductances between the windings. In other words, the leakage unit allows the dissipation of electrical energy from the rectifier branches. In other words, the leakage unit allows the dissipation of energy magnetized in the leakage inductances during charging and discharging of the rectifier elements. 202413275

[0022] 3

[0023] Advantages and embodiments of the invention, which can be used individually or in combination with one another, are the subject of the dependent claims.

[0024] It is advantageous if the primary winding, the first partial secondary winding and the second partial secondary winding are designed as disk windings.

[0025] Designing the windings as disc windings results in a more even distribution of the turns of the partial secondary windings onto their respective corresponding turns of the primary winding. This leads to a harmonically distributed distribution and lower losses. In other words, this significantly reduces the heating caused by eddy currents in the two partial secondary windings, which are generated by the stray fields of the other partial secondary winding. Furthermore, disc windings are taller, thus increasing the available cooling surface area.

[0026] It is advantageous if the discharge unit includes a coupling winding via which the first and second partial windings are magnetically coupled to each other.

[0027] The coupling winding ensures that overvoltages in one sub-secondary winding are dissipated to the other sub-secondary winding without the disadvantages of their close proximity. In other words, the coupling winding allows energy stored in leakage inductances between the windings to be dissipated. The energy required to recharge the rectifier elements is stored in the leakage inductances and conducted directly via the coupling winding to the other sub-secondary winding, which, during its conduction phase, delivers power to an output of the resonant converter.

[0028] It is advantageous if the coupling winding comprises a first partial coupling winding and a second partial coupling winding, wherein the first and the second partial coupling windings are connected in parallel, and wherein the first partial coupling winding is magnetically coupled to the first partial secondary winding and the second partial coupling winding is magnetically coupled to the second partial secondary winding.

[0029] This design ensures excellent magnetic coupling between the two secondary windings. 202413275

[0030] 4

[0031] It is advantageous if the first partial coupling winding is wound around the first partial secondary winding and the second partial coupling winding is wound around the second partial secondary winding.

[0032] This design ensures excellent magnetic coupling between the two partial secondary windings while also allowing for easy manufacturing.

[0033] It is advantageous if the first partial coupling winding is bifilar wound with the first partial secondary winding and the second partial coupling winding is bifilar wound with the second partial secondary winding.

[0034] This design ensures an even further improved magnetic coupling of the two partial secondary windings.

[0035] It is advantageous if the discharge unit comprises a first discharge element, in particular a first diode, and a second discharge element, in particular a second diode, and wherein the first discharge element is arranged in the first rectifier branch and the second discharge element is arranged in the second rectifier branch for the purpose of discharging electrical energy from the respective rectifier branch.

[0036] These discharge elements can be implemented as diodes, transistors, MOSFETs, or similar devices, and ensure that during transient processes in the resonant converter, the energy stored in the leakage inductances of the two secondary windings does not damage the rectifier but can be dissipated. In other words, overvoltages can be dissipated via the discharge elements.

[0037] It is advantageous if the first and second conduction elements are connected to a storage element, in particular a capacitor, which can be charged by the conducted electrical energy.

[0038] This allows the derived energy to be used effectively in the resonant converter, increasing the efficiency of the resonant converter.

[0039] It is advantageous if the storage element is connected to an output of the resonant converter via a buck converter. 202413275

[0040] 5

[0041] This allows for improved utilization of the derived energy, which in turn increases the efficiency of the resonant converter.

[0042] It is advantageous if the energy that can be diverted through the decoupling unit can be diverted to the output via a buck converter.

[0043] This allows for improved utilization of the derived energy, which in turn increases the efficiency of the resonant converter.

[0044] It is advantageous if the distance is at least 3 mm, preferably at least 4 mm, and most preferably at least 5 mm.

[0045] The gaps allow a cooling medium, for example air, to pass through and cool the transformer, especially the two secondary windings, for example by natural or forced convection.

[0046] It is advantageous if the transformer is designed as a shell transformer with a middle leg and the common leg is the middle leg.

[0047] This results in a compact design for the transformer while simultaneously providing optimal cooling.

[0048] The invention will now be described and explained in more detail with reference to the exemplary embodiments shown in the figures.

[0049] Fig. 1 shows a circuit diagram of an exemplary first embodiment of the resonant converter,

[0050] Fig. 2 shows a circuit diagram of an exemplary second embodiment of the resonant converter, and

[0051] Fig. 3 shows an exemplary embodiment of the transformer of the resonant converter in a sectional view.

[0052] Figures 1 and 2 show the circuit diagrams of exemplary first and second embodiments of the resonant converter, respectively. The resonant converter is supplied with a supply voltage, in this example with an intermediate circuit voltage UZK. The first switching element M4 and the second switching element M5, in this example 202413275, are used to connect the circuits.

[0053] The primary half-bridge of the resonant converter is formed by n-channel metal-oxide-semiconductor field-effect transistors (abbreviated "NMOS"). Together with the leakage inductance of the primary winding of transformer T and the resonant capacitor 04, this forms an LC series resonant circuit. The first rectifier element M1 and the second rectifier element M2 form an output-side rectifier, with the first rectifier element M1 connected to the first partial secondary winding L1 of transformer T in a first rectifier branch and the second rectifier element M2 connected to the second partial secondary winding L2 of transformer T in a second rectifier branch. The two partial secondary windings L1 and L2 are connected in a center-tap configuration.In this example, the first rectifier element M1 and the second rectifier element M2 are implemented as n-channel metal-oxide-semiconductor field-effect transistors (abbreviation: "NMOS").

[0054] When the primary half-bridge formed by the first switching element M4 and the second switching element M5 oscillates, the discharged output capacitance of the first and second rectifier elements M1 and M2, respectively, is charged via the coupling between the primary winding L4 and the two partial secondary windings L1 and L2. This magnetizes the leakage inductance of the two partial secondary windings L1 and L2, increasing their electrical voltages. This voltage, or the energy stored in the leakage inductances, can be dissipated via the discharge unit provided in both embodiments. The discharge unit is described in more detail in the descriptions of the embodiments.

[0055] In Fig. 1, the primary winding L6 of the transformer is represented in an equivalent circuit by the inductances of the first auxiliary inductor L4, the second auxiliary inductor L3, the main inductor L5, the first leakage inductor L41, and the second leakage inductor L31. The representation of the primary winding L6 by the various inductances serves only to illustrate the relationships of the leakage inductances and magnetic couplings, and to simulate the circuit. The circuit diagram in Fig. 1 can also be represented using only the primary winding L6, as shown in Fig. 2.

[0056] The primary winding L6 is shown divided into a first auxiliary inductance L4 and a second auxiliary inductance L3, because the primary winding L6 has a first leakage inductance L41 with respect to the first partial secondary winding L1 and a second leakage inductance L31 with respect to the second partial secondary winding L2. The first auxiliary inductance L4 is coupled to the first partial secondary winding L1 via a defined ratio (winding ratio). The second auxiliary inductance L3 is coupled to the second partial secondary winding L2 via a defined ratio (winding ratio).

[0057] 7

[0058] Secondary winding L2 is coupled. The first leakage inductance L41 is the sum of the leakage inductances of the first auxiliary inductor L4 and the first partial secondary winding L1. The second leakage inductance L31 is the sum of the leakage inductances of the second auxiliary inductor L3 and the second partial secondary winding L2. The main inductance L5 is the resulting main inductance of the primary winding L6.

[0059] The essential element in Fig. 1 is the representation of the coupling winding L10, L20, which comprises a first partial coupling winding L10 and a second partial coupling winding L20. In this embodiment, the coupling winding L10, L20, or the first partial coupling winding L10 and a second partial coupling winding L20, is enclosed by the discharge unit. The two partial coupling windings L10, L20 are electrically connected in parallel. The first partial coupling winding L10 is magnetically coupled to the first partial secondary winding L1. The second partial coupling winding L20 is magnetically coupled to the second partial secondary winding L2. The magnetic couplings are indicated in Fig. 1 by lines running from one winding to the winding coupled to it. The magnetic coupling of one of the partial coupling windings with one of the partial secondary windings can be established in various ways.

[0060] One possibility is that the first partial coupling winding L10 is wound around the first partial secondary winding L1 and the second partial coupling winding L20 is wound around the second partial secondary winding L2.

[0061] Another possibility is that the first partial coupling winding L10 is bifilar wound with the first partial secondary winding L1 and the second partial coupling winding L20 is bifilar wound with the second partial secondary winding L2.

[0062] Another possibility is that the first partial secondary winding L1 is wound around the first partial coupling winding L10 and the second partial secondary winding L2 is wound around the second partial coupling winding L20.

[0063] The spatially separated secondary windings are magnetically coupled via the coupling windings, and the energy stored in the leakage inductances from the charging and discharging of the rectifier elements is directly conducted via the coupling of the coupling windings into that part of the secondary winding which is currently in its conduction phase and supplying power to the output of the power supply. 202413275

[0064] 8

[0065] Figure 2 shows an exemplary second embodiment of the resonant converter. In this embodiment, a first leakage element D1 in the form of a diode D1 and a second leakage element D2 in the form of a diode D2 are enclosed by the leakage unit. To dissipate the energy stored in the leakage inductances of the two partial secondary windings L1 and L2, which was stored during the charging and discharging of the rectifier elements M1 and M2 respectively, the first diode D1 is arranged in the first rectifier branch and the second diode D2 in the second rectifier branch. The first diode D1 is connected anode-side to the first partial secondary winding L1 and the first rectifier element M1. The second diode D2 is connected anode-side to the second partial secondary winding L2 and the second rectifier element M2.The two diodes D1 and D2 are connected on their cathode sides to a capacitor 02, which can be charged by the energy derived from the two rectifier branches through diodes D1 and D2. Capacitor 02 is connected to a buck converter formed by a third switching element M3, an inductor L3, and a diode D3. The energy stored in capacitor 02 can be delivered to the output P24 of the resonant converter via the buck converter. In this example, the third switching element M3 is implemented as an n-channel metal-oxide-semiconductor field-effect transistor (NMOS). It is important to note that not the entire output power of the resonant converter flows through the buck converter. Only the energy derived from the rectifier branches by the leakage elements, which was stored during the charging and discharging of rectifier elements M1 and M2, is delivered to the output via the buck converter.

[0066] The first and second rectifier elements M1 and M2, as well as the first, second and third switching elements M3, M4 and M5, are controlled via a control circuit not shown.

[0067] A third embodiment, not shown, combines the first and second embodiments in such a way that the resonant transducer includes a discharge unit comprising both a coupling winding and discharge elements. This third embodiment combines the advantages of the first and second embodiments.

[0068] Fig. 3 shows an exemplary embodiment of the transformer T of the resonant converter in a sectional view. In this embodiment, the windings are rotationally symmetrical about the axis X. The windings are arranged on a rotationally symmetrical support H. The windings together with the support H are on a common leg (not shown) of an iron core of transformer T 202413275.

[0069] 9. The leg runs in an opening formed by the holder H in the direction of the axis X. The two partial secondary windings L1 and L2 are each arranged next to the primary winding L6 in the direction of the axis X, with a distance a between the windings. In this example, the transformer T is designed as a shell-type transformer with a central leg. The common leg on which the windings are arranged is, in this example, the central leg. The coupling winding is not shown in Fig. 3. In one embodiment of the invention, the first partial coupling winding L10 and the second partial coupling winding L20 can, for example, be wound bifilarly with the first partial secondary winding L1 and with the second partial secondary winding L2, respectively.

[0070] 202413275

[0071] Reference symbol list

[0072] L1 First partial secondary winding

[0073] L2 Second Part-Secondary Winding

[0074] L3 Second auxiliary inductor

[0075] L31 Second stray inductance

[0076] L4 First auxiliary inductor

[0077] L41 First stray inductance

[0078] L5 Main Inductance

[0079] L6 Primary winding

[0080] L7 throttle

[0081] L10 First partial coupling winding

[0082] L20 Second partial coupling winding

[0083] T transformer a distance

[0084] H bracket

[0085] X-axis

[0086] D1 First Diode

[0087] D2 Second Diode

[0088] C1 Output capacitor

[0089] C2 First capacitor

[0090] C3 Second capacitor

[0091] C4 resonant capacitor

[0092] M1 First rectifier element

[0093] M2 Second rectifier element

[0094] M3 First switching element

[0095] M4 Second switching element

[0096] M5 Third switching element

Claims

202413275 11 Patent claims 1. Resonance converter comprising a transformer (T) which includes a primary winding (L6) and a secondary winding (L1, L2), wherein - the secondary winding (L1, L2) is divided into a first partial secondary winding (L1) and a second partial secondary winding (L2); - the primary winding (L6), the first partial secondary winding (L1) and the second partial secondary winding (L2) are arranged side by side on a common leg of a magnetic core of the transformer (T); - the primary winding (L6) is arranged between the first partial secondary winding (L1) and the second partial secondary winding (L2); - the first partial secondary winding (L1) and the second partial secondary winding (L2) are each spaced a distance (a) away from the primary winding; - the first partial secondary winding (L1) and the second partial secondary winding (L2) are connected in a center-tap circuit; - the first partial secondary winding (L1) in a first rectifier branch is connected in series with a first rectifier element (M1) and the second partial secondary winding (L2) in a second rectifier branch is connected in series with a second rectifier element (M2); and - a leakage unit is arranged in the resonant converter, via which energy stored in leakage inductances of the partial secondary windings (L1 , L2) during a recharging of the first rectifier element (M1) and / or the second rectifier element (M2) can be leaked.

2. Resonance converter according to claim 1, wherein the primary winding (L6), the first partial secondary winding (L1) and the second partial secondary winding (L2) are designed as disk windings.

3. Resonance transducer according to one of claims 1 or 2, wherein the discharge unit comprises a coupling winding (L10, L20) via which the first partial secondary winding (L1) and the second partial secondary winding (L2) are magnetically coupled to each other.

4. Resonance converter according to claim 3, wherein the coupling winding (L10, L20) comprises a first partial coupling winding (L10) and a second partial coupling winding (L20), wherein the first partial coupling winding (L10) and the second partial coupling winding (L20) are connected in parallel, and wherein the first partial coupling winding (L10) is magnetically coupled to the first partial secondary winding (L1) and the second partial coupling winding (L20) is magnetically coupled to the second partial secondary winding (L2). 202413275 12 5. Resonance converter according to claim 4, wherein the first partial coupling winding (L10) is wound around the first partial secondary winding (L1) and the second partial coupling winding (L20) is wound around the second partial secondary winding (L2).

6. Resonance transducer according to claim 4, wherein the first partial coupling winding (L10) is bifilar wound with the first partial secondary winding (L1) and the second partial coupling winding (L20) is bifilar wound with the second partial secondary winding (L2).

7. Resonance converter according to one of the preceding claims, wherein the discharge unit comprises a first discharge element (D1), in particular a first diode (D1), and a second discharge element (D2), in particular a second diode (D2), and wherein the first discharge element (D1) is arranged in the first rectifier branch and the second discharge element (D2) is arranged in the second rectifier branch for the purpose of discharging electrical energy from the respective rectifier branch.

8. Resonance converter according to claim 7, wherein the first (D1) and the second derivation element (D2) is connected to a storage element (02), in particular to a first capacitor (02), which can be charged by the derivation electrical energy.

9. Resonance converter according to claim 8, wherein the storage element (02) is connected to an output of the resonance converter via a buck converter.

10. Resonance converter according to one of claims 7 to 9, wherein the energy that can be drawn off through the derivation unit can be drawn off to the output via a buck converter.

11. Resonance transducer according to one of the preceding claims, wherein the distance (a) is at least 3 mm, preferably at least 4 mm, particularly preferably at least 5 mm.

12. Resonance converter according to one of the preceding claims, wherein the transformer (T) is designed as a shell transformer with a middle leg and the common leg is the middle leg.

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