Active Clamp Flyback Controller for Zero Voltage Switching

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Solution Overview

Problem

Existing power source devices using flyback transformers of the active clamp type face increased circuit size and cost due to the need for detecting secondary-side load current, leading to inefficiencies and losses in detected resistance.

Innovation Solution

A power source device with a transformer, a primary winding, a secondary winding, a first switch portion, a capacitor, a second switch portion, and a controller that alternately conducts the switches to generate output voltage while detecting current through the first switch portion, ensuring the current does not exceed a threshold, thereby controlling conduction times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If secondary-side load current detection is implemented, then zero voltage switching control is achieved, but circuit size and cost increase

Engineering Contradiction:
Improvezero voltage switching controlVSAvoidcircuit size
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a transmitting circuit as an intermediary component that bridges the primary and secondary sides. This circuit transmits load current information from the secondary side to the primary side, enabling the controller to perform zero voltage switching control without directly detecting secondary-side current. The transmitting circuit acts as a mediator that conveys necessary information across the isolation barrier, resolving the contradiction by providing control capability while maintaining circuit simplicity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a copy of the load current information by detecting it on the secondary side and transmitting it to the primary side. Instead of requiring complex direct detection circuits on the primary side, the system copies the essential current information across the transformer isolation barrier. This copying approach enables accurate control while using simpler, more cost-effective circuit implementation.

Inventive Principle:
Principle #26Copying

2Reliability

If secondary-side load current detection is implemented, then zero voltage switching control is achieved, but cost increases

Engineering Contradiction:
Improvezero voltage switching controlVSAvoidcost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The transmitting circuit serves as a cost-effective intermediary that enables control functionality without requiring expensive direct secondary-side current detection circuits on the primary side. By using this intermediary approach, the patent achieves zero voltage switching control at a lower manufacturing cost compared to implementing full secondary-side detection hardware.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a simple transmitting circuit that uses minimal components (resistors, capacitors, and transistors) to achieve the control function. This approach replaces expensive complex detection circuits with a cheaper, simpler alternative that performs the necessary information transmission task effectively.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Loss of information

If secondary-side load current detection is implemented, then load information is obtained, but loss in detected resistance generates

Engineering Contradiction:
Improveload informationVSAvoidpower loss
Core Design Contradiction:
Loss of informationVSLoss of energy

Solution Approach 1:

The transmitting circuit acts as an intermediary that transfers load information without requiring high-value detection resistors that would generate significant power loss. By using this intermediate transmission approach, the system obtains necessary load information while minimizing energy dissipation in detection components.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct electrical current measurement (which would require power-consuming resistors) with an indirect information transmission method. Instead of mechanically measuring current on the primary side, the system uses electrical signal transmission from the secondary side to convey load information, thereby substituting a power-lossy measurement approach with a more efficient signal transmission approach.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration enables efficient zero voltage switching with a simple circuit design, reducing power consumption and costs by eliminating the need for complex load current detection circuits.

Implementation Method 1

a transformer including a primary winding and a secondary winding

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a circuit including a capacitor and a second switch portion connected in series

Methodology Applied
Scientific EffectCapacitance: Capacitance

Data Source

PatentUS10063157B2Power source device and image forming apparatus
Publication Date: 2018.08.28 CANON KK
  • US10063157B2 patent drawing
  • US10063157B2 patent drawing
  • US10063157B2 patent drawing

AI summary

A power source device includes a transformer including a primary winding and a secondary winding; a first switch portion connected with the primary winding in series; a circuit including a capacitor and a second switch portion connected in series and connected with the primary winding in parallel; a controller for controlling conduction between the first switch portion and the second switch portion, wherein the first switch portion and the second switch portion are alternately conducted to generate an output voltage at a secondary side of the transformer, a detecting portion for detecting a current flowing through the first switch portion. The controller controls conduction of the first switch portion and the second switch portion so that a value of the current detected by the detecting portion does not exceed a threshold depending on conduction times of the first switch portion and second switch portion.