High energy, scalable, pulsed power, multimode multi-filar inductors

Abstract

Embodiments for a multi-wire inductor with at least three switchable windings, with a power distribution winding denoted P1, a suppression distribution winding denoted B, a cladding distribution winding denoted T, switching means for switching distribution between P1, B and T windings; and a capacitor bank, wherein B suppresses back EMF generated by pulsed power, T contains EMF emitted by field emission generated by pulsed power, and wherein input pulsed power input is converted to constant current output to the capacitor bank, such that its duration is extended by the combination of inductor windings and capacitor bank, thereby minimizing peak inductance below inductor saturation point.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application 62 / 964442, filed January 22, 2020, entitled "High-Energy, Scalable, Pulse Power, Multimode Multifilar-Wound Inductor". Technical Field

[0003] The embodiments generally relate to magnetic structures for efficient energy conversion, such as inductors.

[0004] background

[0005] An inductor is defined as any form of magnetic material (i.e., circular, e-core, c-core, d-core, etc.) wound in any way around copper (or equivalent) wires forming an inductive structure; wherein the core can be air or a magnetic material such as ferrite, multilayer iron alloy, powdered iron, or amorphous alloy, or any combination thereof. This also includes nanocrystalline materials.

[0006] Inductors are multifaceted because they can also be wound in parallel with multiple conductors in various configurations to form multifilar windings. The winding nomenclature used herein can be expressed as follows: a two-wire wound inductor can be called a bifilar; a three-wire wound inductor can be called a trifilar; a four-wire wound inductor can be called a quadrifilar, and so on. Furthermore, the nomenclature can alternatively refer to inductors having two or more windings, referred to herein as "multifilar" or, as such, can be indicated by two, three, four, or more windings.

[0007] A novel feature of multi-wire wound inductors is the increased capacitance that attenuates overvoltages (e.g., U.S. Patent No. 4,358,808). In yet another example (e.g., U.S. Patent No. 5,166,869), a two-wire winding practice is applied to eliminate the capacitor, as such windings inherently increase the winding capacitance. In yet another example, a four-wire solution is applied to address the common-mode problem (e.g., U.S. Patent No. 4,679,132).

[0008] Typically, when converting high-voltage electrical energy (i.e., megajoules, MJ) from a high-voltage energy system, the current demand can reach tens of thousands of amperes or more. Sometimes this is controlled by a switching function S supplying current to an inductor L. Meanwhile, the inductance L of the inductor may be mutually exclusive with the copper wire gauge. For example, a toroidal core of a specific size can be calculated as 20 mH for 118 turns, making the winding calculation completely independent of whether it is wound with 20 gauge or 16 gauge copper wire (or equivalent). Because larger gauge copper wire increases the size, weight, cost, and efficiency of the inductor, it also increases its thermal and electromagnetic (EM) characteristics, where EM typically involves the entire EM spectrum, including near- and far-field electric and magnetic fields from ELF (extremely low frequencies) to IR (infrared). In many applications, the generation of these subsequent EMs must be suppressed. Such applications can include military uses, such as autonomous maritime vehicles.

[0009] In carrying out their respective missions, military and civilian services may encounter unforeseen and perhaps last-resort situations requiring the provision of highly reliable, readily available, short-duration, adjustable high energy to assist and / or prevent potential threats to survival. This adjustable high energy can be converted into one or more useful voltages; however, unforeseen high energy demands may further be conditioned on reducing the generation of any potential or possible EM characteristics. Such reduction is a necessary feature in many applications such as military maritime operations.

[0010] For last-resort or other high-reliability requirements, high-energy power systems can include grid, microgrid, and off-grid isolated power and backup applications. Examples include independent backup power for preventing elevator stranding during power outages in high-rise buildings, for temporary lighting and alarm systems, and also for expanding the fuel capacity of diesel / natural gas generators, particularly in buildings and harsh environments such as polar regions.

[0011] Such ultra-reliable, high-availability applications can be met by implementing space and military high-reliability specifications, which are often too expensive and complex. Nevertheless, minimizing the number of components in a system generally ensures the best chance of achieving the highest reliability. For these purposes, the number of components is significantly minimized by eliminating topologies that favor pulse-mode switching (i.e., "buck converters").

[0012] Therefore, what is needed are high-energy, multi-mode, multi-wire wound inductors that convert megajoules of energy into one or more useful voltages while minimizing temperature rise, reducing EM field generation, and minimizing copper wire size, thereby reducing inductor size, weight, cost, and efficiency, while primarily achieving adiabatic loading.

[0013] The topics discussed in the background section should not be assumed to be prior art, but only as a result of their mention in the background section. Similarly, problems mentioned in or related to the topics in the background section should not be assumed to have been previously recognized in the prior art. The topics in the background section merely represent different methods, which themselves may be briefly described in the accompanying drawings.

[0014] In the following figures, similar reference numerals indicate similar structural elements. Although the figures illustrate various examples, one or more embodiments and implementations described herein are not limited to the examples depicted in the figures.

[0015] Figure 1 A ring-shaped core of material, comprising copper (or equivalent) wires for inductors, is shown according to some embodiments.

[0016] Figure 2 It shows Figure 1 A ring-shaped magnetic structure in which a winding of three wires is partially wound around a portion of the ring core from a starting point.

[0017] Figure 3 It shows Figure 2 The fully wound three-wire inductor is shown with start and stop points according to some embodiments.

[0018] Figure 4 A toroidal magnetic core with gaps configured in the core material is shown.

[0019] Figure 5A A pulse power topology diagram using a multi-wire inductor is shown according to some embodiments.

[0020] Figure 5B An inductor with two power windings P1 and P2 and windings T and B, according to an example embodiment, is shown.

[0021] Figure 6 This is a graph illustrating the power versus time relationship between the adiabatic gradient and heat dissipation of a multimode multiline inductor according to some embodiments.

[0022] Figure 7 An open-circuit switching topology diagram of a pulse power, multi-mode, multi-line inductor circuit using a multiplexing switching matrix is ​​shown according to some embodiments.

[0023] Figure 8 A suppression circuit including a directional diode is shown according to some embodiments. Figure 5A The inductor circuit.

[0024] Figure 9This illustrates a containment structure including extension lines according to some embodiments. Figure 5A A schematic diagram of an inductor circuit.

[0025] Figure 10 The positioning relative to the toroidal inductor according to some embodiments is shown. Figure 9 EM-coated windings.

[0026] Figure 11 The use of some embodiments is shown. Figure 5A A multi-wire inductor system for energy conversion.

[0027] Figure 12 The use of some embodiments is shown. Figure 7 A multi-mode, multi-wire inductor system for energy conversion.

[0028] Figure 13 This is a set of diagrams illustrating the setup of a switch array for configuring patterns of inductor circuits according to some embodiments.

[0029] Figure 14 Table 1400 shows, according to some embodiments, different loads for different P1 switching modes.

[0030] Figure 15A It shows Figure 7 The circuit, wherein a specific switch configuration for winding P1 corresponds to Figure 13 1302.

[0031] Figure 15B It shows Figure 7 The circuit, wherein a specific switch configuration for winding P1 corresponds to Figure 13 1306.

[0032] Figure 15C It shows Figure 7 The circuit, wherein a specific switch configuration for winding P1 corresponds to Figure 13 1310.

[0033] Overview

[0034] The embodiments disclosed herein relate to the fabrication, form, and function of pulsed power, multi-mode, multi-wire wound inductors. More specifically, they relate to a scalable multi-mode high-energy pulsed power sensing component implemented with a multi-wire wound magnetic core.

[0035] The disclosed embodiments also relate to the use of multi-wire wound magnetic structures to enhance energy conversion, improve adiabatic loading efficiency, and reduce reverse EMF. More specifically, an effective magnetic structure includes a multi-wire wound core to increase energy conversion, suppress temperature rise, and minimize transient EMF.

[0036] Embodiments of multiple windings in a magnetic structure for dissipating anti-EMF are disclosed. In some embodiments, when the windings are wound in parallel, such a winding can be referred to as a "two-wire" winding, meaning two conductors (wires) connected in parallel, or a "three-wire" winding, meaning three conductors connected in parallel. However, a winding may include more than two or three wires connected in parallel.

[0037] Detailed description

[0038] The following is a detailed description of one or more embodiments, along with accompanying drawings illustrating the principles of the described embodiments. Although various aspects of the invention have been described in conjunction with these embodiments, it should be understood that the invention is not limited to any single embodiment. Rather, the scope is limited only by the claims, and the invention includes many alternatives, modifications, and equivalents. For illustrative purposes, numerous specific details are set forth in the following description to provide a thorough understanding of the described embodiments, which can be practiced without some or all of these specific details, as claimed. For clarity, technical materials known in the art related to the embodiments are not described in detail so as not to unnecessarily obscure the described embodiments.

[0039] It should be understood that the described embodiments can be implemented in a variety of ways, including as a process, apparatus, system, device or component within a larger system, method or article of manufacture.

[0040] Multi-wire inductor

[0041] As a fundamental electronic component, magnetic structure design can involve consideration of certain complex vectors. One of these vectors is magnetic flux saturation, and the B-value of the medium (material) of the magnetic structure. sat Media can be classified into several categories such as ferrites, powders, and ferroalloys, each with its typical B... sat Point. In these materials, the B of ferrite... sat It may be the lowest. Each category of magnetic material has certain advantages compared to other materials. For example, although ferrite has a relatively low B... sat While the Curie temperature is desirable, certain efficient properties of ferrites may be anticipated. Therefore, ferrites may possess certain superior parameters, but may have the lowest Bc. sat For certain high-power / high-current applications, a lower B... sat It can present a huge B max (Keep below B) sat Limitations. Pulse power, multi-mode, multi-wire inductor embodiments overcome some of these limitations.

[0042] Although it is possible to design and produce more Bsat Durable material (i.e., powder), in which this ferrite is designed B max It can exceed B sat For example, there may be a list of preferred materials, such as: ferrite, first; powder, second; and so on. In this case, if ferrite cannot handle the power of the design, the designer can move down to the next preferred material. The embodiments of the multi-wire inductors described herein are not limited to only one such magnetic medium or material.

[0043] Used to mitigate the low B content of ferrites for high current applications. sat One possible solution is to insert gaps into the magnetic structure. More specifically, certain magnetic structures, such as those in the form of rings, can be adapted for gap practice. The embodiments of the multi-wire inductors described herein can be used with magnetic structures with or without gaps.

[0044] Examples include high-energy, multi-mode, multi-wire-wound inductors that convert megajoule-scale energy into single or multiple useful voltages. These inductors are characterized by minimizing temperature rise and reducing EM field generation, while also minimizing copper winding wire size. This reduces the inductor's size, weight, cost, and efficiency, and enables adiabatic loads.

[0045] In this embodiment, the inductor is configured as a toroidal ferrite inductor L. Figure 1 The diagram shows a ring-shaped core comprising a material such as ferrite, with copper (or equivalent) wire wound around the material. Figure 1 As shown, a core can be a single integral part or a composite unit consisting of two or more stacked cores. For Figure 1 The example shows two stacked toroidal cores, 101 and 102, but the embodiment is not limited to this; any actual number of cores can be stacked depending on application needs and limitations. Multiple or composite cores 101 and 102 can be connected or secured together using known connection methods, or they can simply be placed together and connected by wire windings.

[0046] In this embodiment, the toroidal core 100 is wound with multiple individual copper wires. The windings can be two-wire (two conductors), three-wire (three conductors), four-wire (four conductors), etc., to create a multi-wire inductor. The embodiments described herein are directed to a three-wire inductor; however, it should be noted that other numbers of conductors are also possible. Figure 2 It shows Figure 1A toroidal magnetic structure 100 is constructed in which a set of three wires are partially wound around a portion of a toroidal core from a starting point to form a winding 202. In Figure 304, the three wires are shown as 304, 306, and 308, and may have different colors or chromaticities such as yellow, green, and red to distinguish themselves. They are wound in an alternating manner, such as green-yellow-red-green-yellow-red (or 304-306-308-304-306-308...), and so on. Depending on the application requirements, the wires may have a uniform gauge and thickness, and will be described herein as copper, but other similar materials may also be used. The three wires are typically wound as a single layer on the core 100 in a prescribed direction (i.e., clockwise or counterclockwise) as indicated by the dashed arrow 210. Winding can begin by securing one end of the wire with adhesive, tape (as shown), or other similar securing means.

[0047] Figure 3 A fully wound three-wire inductor 300 according to some embodiments is shown. In this embodiment, three wires begin at starting points indicated by 304a, 306a, and 308a. The wires are wound around a loop core in a predetermined direction (clockwise or counterclockwise) until a desired end (or stop) point is reached. The wires are then cut to produce end leads 304b, 306b, and 308b. Two sets of leads 304a-306a-308a and leads 304b-306b-308b are used as input and output leads, respectively, when the inductor is used in a circuit, as follows: Figure 5A As shown.

[0048] The wire gauge and spacing between individual conductors of 304, 306, and 308 can be varied. That is, they can be wound close together or with a certain amount of spacing between them. They can have the same or different gauges, and they can be insulated or uninsulated, depending on the situation. The winding can also extend as far along the loop core as possible. Therefore, as... Figure 3 As shown, a gap 310 exists between the start and end of the conductor. The gap 310 can be formed by any distance between the start and end of the conductor, as needed. For the illustrated embodiment, a relatively small gap 310, such as about 5 to 10 degrees along a circle defined by an annular surface, is provided. In other embodiments, a larger gap, such as 15 to 20 degrees, or any other gap, can be used. This gap 310 minimizes H / B field disturbances that may occur when the end of the conductor is directly adjacent to or against the start of the conductor. Depending on application needs and limitations, the configuration of the gap 310 in proportion to its area relative to the total area of ​​the core and / or the number of windings can be varied.

[0049] As mentioned above, ferrite inductors may exhibit low B under high current. satOne way to mitigate this effect is to insert gaps in the magnetic structure. Figure 1 The toroidal magnetic structure is well-suited for gap configurations. Therefore, in embodiments, the toroidal core itself can form a gap, creating a notch or slot within the ferrite body of the core. This gapped toroidal coil represents another class of inductive B / H operation. In this case, the saturation curve is shifted somewhat to allow more current to flow. The gap can have any suitable size, but generally, the inductance decreases as the gap size increases. Therefore, the wider the gap, the lower the inductance. Furthermore, for gapped toroidal coils, it should be noted that most of the energy J is stored in the gap. Figure 4 A toroidal magnetic core with gaps is shown. (Example) Figure 4 As shown, the magnetic core 14 has a gap 16. The size of the gap 16 can be set to optimize and reduce the low B content of the ferrite core. sat The advantageous effect of the points. When the gap is formed in this way, the orientation of windings 304, 306 and 308 and any spacing 310 between the start lead and the end lead should be configured accordingly, so that the windings cover the gap or are within the winding spacing if necessary.

[0050] As used herein, multi-wire winding 202 refers to parallel magnetic conductors, which means an article comprising at least two magnetic conductors that are partially parallel to each other. These magnetic conductors may be formed into a strip, wherein each conductor is electrically isolated from the other conductors by an insulating material. In some embodiments, the magnetic conductors may be individually coated with an electrical insulator or not. The magnetic conductors may be embedded parallel to each other or non-parallel between two insulating materials, which are brought together to bond the conductors and the insulating materials together, thereby creating a strip of parallel-bonded magnetic conductors. The insulated magnetic conductors may then be arranged parallel to each other and may be bonded together to form a strip of parallel-bonded magnetic conductors. The magnetic conductors may be primarily composed of metal, such as copper or aluminum, or an alloy of two or more metals, and may consist of layered conductors, which may comprise an inner layer of aluminum and an outer layer of copper. Another alternative layered conductor may comprise an inner layer of copper and an outer layer of aluminum.

[0051] Pulse power multi-mode circuit

[0052] In this embodiment, a multi-wire (tri-wire) inductor 300 is used in a pulse power topology. Figure 5A A pulsed power topology diagram using a multi-wire inductor is shown according to some embodiments. In such a pulsed power circuit 500, inductor L1 can apply DC pulse energy to power winding P1 via switch S1 in a pulsed power switch single-pole ungrounded configuration. For Figure 5AIn the illustrated embodiment, the three windings of inductor 300 (L1) are designated as P1 (for the power winding), B (for the two-wire winding), and T (for the three-wire winding). The B winding is used to reduce the reactive power caused by the trailing edge of the power pulse transmitted by switch S1. The T winding is used to reduce the remaining reactive power, which also effectively suppresses the EMF emitted by the inductor.

[0053] P1 power winding refers to the first or only power winding in a three-wire inductor. If more than three windings are used, additional power lines P2, P3, etc., can be used. Figure 5B An example is shown, illustrating an inductor 510 with two power windings P1 and P2, as well as T and B windings. Any number of power windings, as denoted as P1 to Pn, can be provided.

[0054] In this embodiment, the thermal resistance of the ferrite triple-wire loop is increased to a level that prevents a temperature rise in the heat transfer copper wire even when megajoules of energy are switched to L1, thus achieving a certain degree of adiabatic loading. This is a result of the inductor inductance μ, which can be adjusted during the thermal-switching time t. T Inside. Figure 6 This is a graph showing the energy (in Joules) versus time between the adiabatic gradient and heat dissipation of a multimode multi-wire inductor according to some embodiments. Figure 6 In the diagram, the x-axis (V) represents time t. T The y-axis (P) represents the current I (in terms of energy in joules). As t... T As I increases, the power on P1 shifts toward the isotherm; or better yet, there is a more likely temperature change. In graph 600, gradient 606 separates the adiabatic region 602 from the heat transfer region 604. The amount of work done 608 is derived by curve 610 defined within gradient 606 between two specific points along the time scale (x-axis). The inductor embodiment requires relief such that power dissipation is generated by the following equation 1.0:

[0055] I 2 R*θja*Duty cycle = Temperature rise [Equation 1.0]

[0056] In Figure 600, the adiabatic process region 602 represents the area where energy is transferred from circuit 500 only as work without any heat or mass transfer.

[0057] like Figure 5AAs shown, inductor L1 has a set of input terminals to three windings T, P1, and B, and a set of output terminals from the three windings T, P1, and B. These terminals are designated as input terminals 1, 2, and 3, and output terminals 4, 5, and 6. Therefore, winding T has input lead 1 and output lead 4, winding P1 has input lead 2 and output lead 5, and winding B has input lead 3 and output lead 6. Regarding... Figure 3 The physical inductor 300 has the following wire leads at the input terminals: 304a=1, 306a=2, and 308a=3; and at the output terminals: 304b=4, 306b=5, and 308b=6. In embodiments, the use and configuration of these different input and output leads in a circuit such as circuit 500 provides multi-mode functionality for the inductor. That is, the mode of inductance within the circuit can be changed by switching between different input and output leads. For example, by switching the P1 winding from line 1 to line 2, the duty cycle can be significantly reduced.

[0058] In this embodiment, the switching function between the three windings is achieved through a multiplexed switching matrix. Figure 7 An open-circuit switching topology diagram of a pulse power, multi-mode, multi-line inductor circuit using a multiplexed switching matrix is ​​shown according to some embodiments. Figure 7 As shown, circuit 700 includes a set of three multiplexing switching matrices, denoted as 704a, 706a, and 708a on the input side, and 704b, 706b, and 708b on the output side. Each of the three sets has three switches, denoted as S2a, S2b, and S2c. The following section discusses... Figure 13 and Figure 14 The different switching modes are described in more detail.

[0059] Multi-mode functionality goes beyond simply switching P1 between windings. For example, an embodiment could switch the B winding to be connected in parallel with P1, thereby effectively providing P1 and P2 windings for even higher power conversions. Similarly, a parallel T winding could be provided.

[0060] Although the embodiments describe the use of a single three-wire inductor, additional multi-mode functionality is made possible by adding a second three-wire wound inductor or other additional multi-wire wound inductors.

[0061] This provides a degree of scalability for circuit 700, where the number of possible combinations is limited only by the possible arrangement of windings and inductors. This provides an expansion of the power stage over a significant range.

[0062] like Figure 5A As shown, circuit 500 includes an enclosure structure 502 and a suppression structure 504. Figure 7In the multi-mode embodiments, these correspond to the covering component 702 and the suppression component 701, respectively. In one embodiment, the suppression component 701 includes a diode to provide a degree of EMF suppression.

[0063] Figure 8 A suppression circuit including a directional diode 802 is shown. Figure 5A The inductor circuit. Diode 802 in circuit 800 can be implemented as any suitable diode device or other current-blocking circuit. In the typically high-voltage, high-power applications of the toroidal inductor 300, suppression circuitry or components must always be provided and enabled. This is because high voltage spikes generated by the EMF effect can damage or destroy related electronic equipment in the system. Although Figure 8 A diode device is shown as a suppression circuit, but the embodiment is not limited to this, and other devices including semiconductor circuits can also be used. However, semiconductor switching requires expensive components due to the suppression of high stray voltages, but cost is not usually guaranteed; therefore, a switching diode 802 is usually sufficient.

[0064] The covering component 702 is also configured to provide EMF suppression. This is achieved by generating a reverse magnetic flux, causing the EMF in each winding to be canceled, thereby reducing the EM near-field and far-field generated during the pulsed power duty cycle. In an embodiment, the covering circuit includes a T-winding reinforcement implemented by an extended copper wire wound around the outside of the toroidal coil. This wire is laid in a circular manner on top of the toroidal coil and in layers opposite in direction to the P1, B, and T windings. Thus, EM covering is achieved by the extended T-winding, which is encapsulated or packaged as part of the toroidal coil structure 300. The EM covering winding can be located on one or both sides of the toroidal coil and operates by canceling reactive EM transmission through reverse current. Figure 9 This illustrates a covering structure including an extension wire 902. Figure 5A A schematic diagram of the inductor circuit. As shown in circuit 900, wire 902 is coupled to the end lead of the T winding and extends above the circuit and the toroidal coil itself.

[0065] Figure 10 The positioning relative to the toroidal inductor according to some embodiments is shown. Figure 9 EM-coated windings. For example... Figure 10 As shown, the coiled wire winding 1002, connected to the T-winding of inductor 1000, is laid along the top of the inductor. The wire can be placed on either side of the inductor. As shown, an additional EM-coated winding 1004 can also be provided on the opposite side of the inductor. Depending on the inductor design and application requirements, one or more coated wires can have any suitable gauge, length, and composition.

[0066] As mentioned above, both suppressor components and encapsulation components help to mitigate or eliminate problems caused by the reverse EMF effect. Reverse EMF generally refers to the induced electromotive force (EMF) that is opposite in direction to the induced current, and is a significant issue for both the static and dynamic operation of inductive circuits in high-energy applications such as large generator sets.

[0067] EMF is an electromagnetic force or field, also known as electric potential. When a changing current is applied to a wire-wound magnetic structure, a reverse EMF generated by the decay of the inductor's B field when the switch is open will produce a transient EMF at its switch contacts. In many cases, this transient EMF effect is undesirable because it tends to adversely affect connected and / or other adjacent components. For example, a transient EMF of a relay coil acting on the on / off switch that controls the operation of its magnetic structure may cause arcing on its metal contacts. This adverse transient impairs energy efficiency. However, exactly how much energy is lost depends on the circuit topology and physical configuration of the magnetic structure. More importantly, AC transients follow one set of energy loss calculations. DC transients follow another set of energy loss calculations. The example embodiments of the aforementioned DC transient energy loss calculations are example embodiments of certain inductors having cores including, but not limited to, powder or ferrite materials. Furthermore, such cores can be formed in many geometries, such as, but not limited to, C-cores, E-cores, and toroidal forms.

[0068] By replacing the E / C type wound inductor with a toroidal (ringed coil) wound inductor, the efficiency measured in certain inductors under a certain test condition was improved. Simultaneously, a 1200V vacuum relay S1 was replaced with a 600V MOSFET switch. Clearly, the MOSFET, as a semiconductor, is likely more susceptible to transient EMF anomalies than the vacuum relay it replaced. This is illustrated by the derivative: -L(dI / dt), where L is the inductance, I is the current, and t is time. The negative sign (-) indicates an anti-EMF. To illustrate the different time ranges, the replaced vacuum relay contacts open and close in milliseconds (ms), while the MOSFET can be enabled and disabled in microseconds (μs). The fundamental electromagnetic (EM) elements are similar to Ohm's law V = I × R (therefore, when S1 is open, the current remains constant; only the voltage necessarily changes). Therefore, it is evident that V in a transient EMF will be potentially many times more destructive, or in other words, generally becoming shorter with t.

[0069] One way to improve dangerous transient EMF is to add a buffer. However, buffers are limited to specific voltages. That is, certain types of high-energy capacitor storage require high voltages, such as: J = CV 2 / 2, where J = energy in joules, V = voltage, and C = capacitance. This high voltage drops exponentially; for example, a 50% voltage drop corresponds to 75% of its energy (or voltage / energy swing), significantly increasing the design complexity of varistor circuits. However, it can also make the buffer circuit more efficient. Buffer circuits are not limited to diodes, but can include metal oxide varistors (MOVs). Many circuit designers use combinations of these components to create buffers.

[0070] Another method to improve transient EMF is multi-wire magnetic windings, as described in this paper. The application of multi-wire windings has been known since the dawn of electronics. Multi-wire windings refer to parallel-wound conductors. For example, two-wire converters are considered the most promising candidates for the lowest-cost power electronic converters, requiring only one ground reference switch per phase for unipolar excitation, or two ground reference switches per phase for bipolar excitation. Various power converter topologies can support a variety of two-wire magnetic structures.

[0071] However, diodes and MOVs are more efficient if and only if the anti-EMF can be suppressed or further suppressed at the magnetic structure, thereby dissipating less energy, or even no energy dissipation at all. Therefore, a better approach to suppressing transient EMFs is to suppress the anti-EMF at the magnetic structure. Figure 5A The suppressor and encapsulation structure in this paper provide an effective method to suppress back EMF at the magnetic structure. It should be noted that the magnetic structures described herein include, but are not limited to, any inductive device, but exclude conventional coil-driven mechanical relays.

[0072] An example embodiment is described, in which the inductor is toroidal, ungrounded, and biased at a DC level with unipolar excitation. Such a device can be used in conjunction with a switch or switching matrix and a high voltage (HV) and service bank, as described in U.S. Patent Nos. 9,287,701 and 9,713,993. One side of the switch can be connected to the HV bank, and the other side can be connected to the toroidal inductor L1. Therefore, S1 can be opened (enabled) for a set period T or otherwise closed. Thus, when S1 is enabled, a DC pulse provides excitation across the high voltage side of L1. The low voltage side of L1 is connected to the SV bank. Regarding certain L1 issues, firstly, assume that the ferrite toroidal inductor is subjected to a large current I, possibly 100 A or higher, with an inductance of 1.0 H (Henry), and the following Equation 2.0:

[0073]

[0074] In the equation above, the unit is cm. It equals MPL (magnetic circuit length), OD is the outer diameter of the toroidal coil, and ID is the inner diameter of the toroidal coil.

[0075] For high-energy, high-current applications, any magnetic structure must meet the constraints imposed by Equation 3.0 below:

[0076]

[0077] In the equation above, H on the left, expressed in Oersted (Oe), equals the source EMF. On the right, it equals the circular dimension of the toroidal coil, expressed in centimeters. The relationship between the product of the number of windings and the peak current (N multiplied by I) and the number of windings (Note: 0.4π represents the conversion between the MKS and CGS counting systems).

[0078] The number of turns N can be obtained using one of several methods (such as by using an online inductance calculator). For copper wire gauge 'g', let's assume it's 10g or 8g for 100A. Therefore, the number of turns determines the wire length. Once N is determined, H can be determined using the equation above.

[0079] For example, if I = 100 A, H can be easily obtained as approximately 70 Oe. Here, ferrite saturates at around 15 Oe. Some tests show that, at what is considered to be three times the peak current B... sat In the case of point B, it is not saturated, but conversely, the actual peak current result is at B. sat point within.

[0080] The slope of curve 200 is the integral of energy over time, which decreases to approximately the integral given in Equation 4.0 below:

[0081]

[0082] The peak current of the waveform slope is much smaller than the assumed static calculation indication. Therefore, the two-wire wound inductor (L1) provides two properties. First, it mitigates reverse EMF; second, it increases B when coupled to the SV capacitor bank. sat Internal energy conversion.

[0083] Some tests also show that temperature rise is little or nonexistent during inductor operation. Firstly, in a toroidal coil wound with ferrite copper wire, the main resistance comes from the copper wire. Mathematically, temperature rise equals the square of the current (I) multiplied by the resistance of the copper wire multiplied by the time the current passes through the inductor, then divided by the capacitance. Therefore, as shown in Equation 5.0:

[0084] ΔT=I 2 Equation 5.0 for TΔt / C.

[0085] This temperature rise effect is represented by adiabatic loading. That is, the energy conversion time is very short, thus preventing heat dissipation. Therefore, in addition to the two properties mentioned above, a relatively low Curie temperature point for a given ferrite provides a third and important property of adiabatic loading.

[0086] Energy conversion system

[0087] As mentioned above, Figure 5A Pulsed power, scalable, multi-mode, multi-line inductor circuits can be used in energy conversion systems, such as high-energy capacitor conversion systems. Figure 11 The use of some embodiments is shown. Figure 5A A multi-wire inductor system for energy conversion. For example... Figure 11 As shown in Figure 1100, a monitoring unit 1104 is positioned between a high-voltage (HV) group and a service group (SV) 1106. The HV group has two subgroups, Group A and Group B, each containing numerous stacked supercapacitor cells and a two-segment switch to convert energy within and between cells in each subgroup. The SV group segment 1106 has an SV group storage system coupled to a load 1112 via a load switch S5. Energy transfer to the SV group 1106 is controlled via switches S4 and S1 and an inductor L1. In this embodiment, L1 is a three-wire wound toroidal inductor 300 and is located in the suppression / coating circuit 1108 and corresponds to... Figure 5A The circuit shown.

[0088] Figure 11 This is a block diagram illustrating the monitoring, switching, and inductor connection to the SV group according to some embodiments. As shown in Figure 1100, the S4 group switch selects between group A and group B in the HV group segment. This switch setting, together with a control signal from the monitoring unit 1104, controls the state of switch S1, which engages or decouples inductor L1. Energy from the HV group segment is fed to SV group 1106 via inductor L1 (when switch S1 is closed) and to load 1112 via load demand switch S5. For example, as... Figure 11 As shown, the SV group has a voltage maintained between 115V and 120V. The SV group is shown at 120V, and the charging trigger point is set at 115V. Figure 1100 illustrates the separation designed to emphasize the ability to control the voltage at 117.5V + / - 2.5V.

[0089] Such as Figure 7 As shown, the inductor circuit 1108 of system 1100 can be implemented by a multi-mode, multi-wire inductor circuit to provide a variety of options for inductor operating modes. Figure 12 The use of some embodiments is shown. Figure 7 A multi-mode, multi-wire inductor system for energy conversion. For example... Figure 12As shown, system 1200 includes a three-wire wound inductor L1, which has a suppression structure and a wrapping structure, and is combined with a switching matrix, as follows: Figure 7 As shown. This circuit 1208 is used by a monitoring circuit to control the flow of power to the load through the HV and SV groups, as described above. Figure 11 As stated above.

[0090] Switch mode

[0091] As described above, the embodiments include a switching matrix that sets the circuit containing the multi-line inductor to one of several different modes. These modes are used to expand the duty cycle of the circuit to optimize... Figure 6 The adiabatic gradient and heat transfer divergence are shown in the figure. (This can be...) Figure 6 Figure 600 shows that the curves of adiabatic gradient and heat transfer divergence indicate that increasing the duty cycle or bringing the energy close to this gradient may cause heat absorption in the windings. Regarding Figure 12 The switching matrix and inductor circuit 1208 mean that switching winding P1 to an adjacent winding, at least theoretically, significantly reduces the duty cycle by half (the actual duty cycle reduction depends on variations in the circuit and components). Utilizing the three-wire inductor 300 of circuit 1208, the three windings allow for a further reduction in the duty cycle. Allowing winding P1 to switch between other windings (T and B) reduces the duty cycle, thereby allowing for a reduction in the size of the conductors including the windings and a more uniform increase in power across the inductor. This is essentially a vector transformation.

[0092] To further extend this feature, in some embodiments, the pulse power on the inductor winding can be such that, for a current I, there can be heat energy I absorbed by the inductor. 2 R represents the loss. The main (but not all) variables are given by Equation 6.0, where the loss (or heat source), the thermal resistance of the inductor, and its thermal vulnerability variables can be expressed as:

[0093] I 2 Equation 6.0: R x(θ=ΔT / P)x DC

[0094] In this equation, R is the total resistance of the winding; θ = ΔT / P represents the thermal resistance of the inductor, and DC is the duty cycle. The duty cycle of the pulse power's on-time is t. on / (t on +t off This is the ratio of its off-time. Generally, the lower the DC value, the less susceptible the inductor is to heat absorption. Conversely, the higher the DC value, the more likely the inductor is to be susceptible to heat transfer. Figure 6 These effects are summarized in the paper, which shows that curve 604 on the left is the adiabatic load boundary or gradient, and curve 602 on the right is the heat transfer absorption or divergence.

[0095] In embodiments where a switching matrix is ​​used to allow the power winding P1 of a multi-wound inductor to switch between windings, the duty cycle can be reduced, thereby further protecting the inductor from temperature rise. Therefore, for example, by switching P1 to an adjacent winding, the duty cycle is obviously (theoretically) reduced by half. Figure 12 The embodiment allows P1 to switch between multi-wire windings between (1) SV group charging cycles or between (2) power pulses, denoted as R. 负 These modes are denoted as P1+C (P1+charging) mode, used for switching in case (1), and P1+R. 负载 The (P1+pulse) mode is used to switch in case (2), where + indicates that P1 has been switched.

[0096] Each of these two modes can be further subdivided into power characteristics that are essentially controlled by load 1212. If it is less than full load (i.e., the maximum value of the design), no switching is required. Figure 14 Table 1400 illustrates different loads for different P1 switching modes according to some embodiments. As shown in Table 1400, the modes are as follows: Mode P1+C is continuous full load; Mode P1++C is continuous full load, where ++ indicates continuous switching of P1 between charging SV groups; Mode P1+R 负载 It is an occasional overload; mode P1++R 负载 It is an intermittent overload, and mode P1++P1 is the last means of power, which switches the two windings in parallel.

[0097] about Figure 12 Typically, the duty cycle varies relative to the load 1212 and is controlled by the total capacitance of the toroidal winding plus the SV group 1210. That is, the energy converted per pulse plus the number of pulses required to charge the SV group to the useful voltage. Therefore, for example, if the SV group size (in terms of capacitance) is set to 125V, such that a constant 15kJ load takes 5 seconds to discharge to 114V, then a 7kJ load will take 10 seconds to discharge to 114V. However, if the load demand is 30kJ for a short period, the circuit must activate S1 every 2.5 seconds. This demonstrates that a wide range of duty cycles can exist. Figure 12 In some embodiments, the multi-mode (or duty cycle extender) mechanism allows for a wide range of duty cycles.

[0098] Figure 13 This is a set of diagrams illustrating the configuration of switch arrays according to some embodiments to arrange inductor circuits. Figure 13 In the text, S21, S22, and S23 represent... Figure 7Figure 700 shows three multi-mode switches. The pin assignments of these switches are as follows: Figure 13 The diagrams 1302, 1306, and 1310 are used for identification. Each of these diagrams switches the connection between the P1 winding and the suppression and encapsulation circuits according to the corresponding circuit diagrams 1304, 1308, and 1312. Therefore, diagram 1302 shows the pin assignments for switches S21a, S22a, and S23a for circuit 1304, diagram 1306 shows the pin assignments for switches S21b, S22b, and S23b for circuit 1308, and diagram 1310 shows the pin assignments for switches S21c, S22c, and S23c for circuit 1312. Figure 8 As shown, the suppression winding is short-circuited and can optionally be connected via a directional diode. Furthermore, as mentioned above, the wrapping winding extends in a circular pattern at the top and bottom of the toroidal coil and is optional. For noise levels such as approximately 40 dBm, this can be doubled or even tripled.

[0099] The switching matrix allows the P1 winding to be switched between three windings T, B, and P. The goal is to switch P1 such that if the #1 winding at P is driven by adiabatic load and heat transfer temperature rise... Figure 6 The boundaries shown in each chart 600.

[0100] Figure 15A , Figure 15B and Figure 15C It shows Figure 7 The circuit 700 has a specific switching configuration for winding P1, and Figure 13 The corresponding diagrams 1302, 1306, and 1310 are shown. For these diagrams, all switches are one of three and are shown in the off position.

[0101] Figure 15A It shows that it has the corresponding Figure 13 The 1302 is configured with a specific switch for winding P1. Figure 7 The circuit diagram shows the connection of winding P1 to pins 1 to 4 of circuit 800.

[0102] Figure 15B It shows that it has the corresponding Figure 13 The 1306 has a specific switch configuration for winding P1. Figure 7 The circuit diagram shows the connection between winding P1 and pins 2 to 5 of circuit 800.

[0103] Figure 15C It shows that it has the corresponding Figure 13 The 1310 has a specific switch configuration for winding P1. Figure 7The circuit diagram shows the connection between winding P1 and pins 3 to 6 of circuit 800.

[0104] Figures 15A-15C The switching configuration provided is for illustrative purposes only, and other switching circuits and configurations may also be used to switch the windings of the multi-wire toroidal inductor 300 according to other embodiments.

[0105] In embodiments, a temperature sensor may be included or associated with each winding. The temperature sensor may be embodied as a thermistor RTD (resistance temperature detector). This sensor is used to measure temperature and may consist of a thin, pure metal wire (e.g., nickel, copper, platinum) wound around a core (e.g., ceramic or glass). It measures temperature as a function of resistance. In embodiments, the temperature sensor may also be implemented as a wide-angle thermal camera to cover the internal region of the toroidal coil. Multiple thermistors may also be placed between the outer windings. Placement between the inner windings is also possible, but there is typically more space between the outer windings due to the possible sinusoidal effect of the tightly packed inner windings. The temperature sensor detects a temperature increase exceeding a defined threshold during inductor use. Any such temperature increase must be a result of the P1 winding, but identifying the exact winding is unnecessary. It is sufficient to detect a specific temperature rise throughout the entire inductor. Such a temperature increase can be used to trigger switching of P1.

[0106] While some example configurations and components have been described and certain embodiments illustrated, it should be understood that the embodiments are not limited thereto, and any actual configuration, composition, operating range, or component selection is possible. Similarly, certain specific values ​​and operating parameters are provided herein. These examples are for illustrative purposes only, and the embodiments are not limited thereto. Those skilled in the art can implement the described functionality using any suitable alternatives.

[0107] For clarity, the processes and methods described herein have been illustrated with specific flows; however, it should be understood that other sequences are possible without departing from the spirit of the invention, and some processes and methods can be performed in parallel. Furthermore, the steps can be subdivided or combined.

[0108] Unless the context otherwise requires, the words “comprise”, “comprising”, etc., in the description and claims shall be interpreted in the sense of inclusion, not in the sense of exclusion or exhaustion; that is, “including, but not limited to” in some sense. The use of singular or plural terms shall also include the plural or singular, respectively. Additionally, the words “this article,” “below,” “above,” “below,” and similar terms refer to the entire application and not any particular part thereof. When the word “or” is used to refer to a list of two or more items, the word covers all of the following interpretations: any item in the list, all items in the list, and any combination of items in the list.

[0109] All references cited herein are incorporated herein by reference. While one or more implementations have been described by way of example and according to specific embodiments, it should be understood that one or more implementations are not limited to the disclosed embodiments. Rather, the invention is intended to cover various modifications and similar arrangements that will be apparent to those skilled in the art. Therefore, the scope of the appended claims should be interpreted in the broadest possible way to include all such modifications and similar arrangements.

Claims

1. A multi-wire inductor having at least three switchable windings, comprising: The power distribution winding is represented as P1; The suppression component, denoted as B, is assigned a winding. The cladding component, denoted as T, is assigned windings. A corresponding temperature sensor is associated with each P1 winding, B winding, and T winding; A switching device for switching the distribution among the P1 winding, B winding and T winding; as well as A capacitor bank coupled to the inductor; Wherein, the B winding suppresses the anti-EMF generated by the pulse power and input to P1, the T winding contains the field emission EMF generated by the pulse power, and wherein the input pulse power input is converted into a constant current output to the capacitor bank, such that its duration is extended by the combination of the inductor winding and the capacitor bank, thereby minimizing the peak inductance below the saturation point of the inductor.

2. The multi-wire inductor according to claim 1, wherein, The switching device switches the distribution among the multi-wire windings between service voltage group charging cycles or between power pulses of the pulse power.

3. The multi-wire inductor according to claim 1, wherein, The P1 winding, B winding, and T winding are wound around the core adjacent to each other.

4. The multi-wire inductor according to claim 3, wherein, The first end of each winding forms a first lead, and the second end of each winding forms a second lead.

5. The multi-wire inductor according to claim 4, wherein, The windings are wound around the inductor such that the second lead of each winding terminates on the core at a predetermined distance from the first end of each winding.

6. The multi-wire inductor according to claim 5, wherein, Each winding includes copper wires, and the core is either air or ferrite material.

7. The multi-wire inductor according to claim 1, wherein, The suppression component includes a directional diode.

8. The multi-wire inductor according to claim 1, wherein, The covering component includes a section of coiled wire disposed along at least a first surface of the inductor.

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