Asymmetrical DC-DC Converter with Multi-Core Transformer
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Solution Overview
Problem
Existing DC-DC converters face limitations in high-voltage, high-power applications due to inefficient power semiconductors, need for galvanic isolation, and challenges in manufacturing transformers with high turns and frequencies, leading to increased losses and reliability issues.
Innovation Solution
An asymmetrical DC-DC converter design with modular, compact high-voltage modules and a single low-voltage module based on a transformer with multiple magnetic cores, allowing for high-frequency operation and efficient energy transfer with reduced components and control complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transformer with high turns ratio and high frequency is used for galvanic isolation in high-power DC-DC conversion, then galvanic isolation is achieved, but losses in magnetic materials increase significantly
Solution Approach 1:
The patent divides the single high-power transformer into multiple lower-power transformers, each operating at reduced power levels. This segmentation allows each transformer to operate more efficiently with lower magnetic material losses while collectively providing the required galvanic isolation for high-power DC-DC conversion.
Solution Approach 2:
The patent introduces intermediate voltage levels and multiple transformer stages as mediators between the high-voltage and low-voltage sides. This multi-stage approach with intermediate buffers reduces the stress on individual transformers, lowering magnetic material losses while maintaining galvanic isolation.
2Power
If PWM with extreme high-ratio duty cycles is used for voltage transformation, then voltage conversion is achieved, but efficiency decreases and malfunctions occur due to very short conduction times
Solution Approach 1:
The patent segments the single extreme duty cycle transformation into multiple moderate duty cycle stages. Each transformer stage operates with a reasonable duty cycle range, avoiding the efficiency losses and malfunction risks associated with extreme high-ratio single-stage PWM conversion.
Solution Approach 2:
The patent employs periodic switching actions across multiple transformer stages, where each stage operates in a complementary periodic manner. This distributed periodic action maintains continuous power transfer with better efficiency compared to single-stage extreme duty cycle PWM.
3Power
If high voltage high power turn ratio and high frequency are combined in a centralized transformer, then voltage transformation is achieved, but manufacturing becomes a technological challenge
Solution Approach 1:
The patent divides the single high-power high-frequency transformer into multiple lower-power modular transformers. Each module has simpler manufacturing requirements with lower voltage and power ratings, making them easier to manufacture while collectively achieving the required high-voltage high-power transformation capability.
Solution Approach 2:
The patent employs modular dynamic configuration where multiple transformer units can be independently manufactured and then assembled. This dynamic modularity allows standardization of manufacturing processes for each module, reducing the technological challenge compared to manufacturing a single custom high-power transformer.
4Reliability
If a centralized high-power high-frequency transformer is used, then galvanic isolation is provided, but the device becomes bulky and specific for each situation
Solution Approach 1:
The patent segments the single bulky centralized transformer into multiple smaller modular transformers. This segmentation reduces the overall device footprint while maintaining galvanic isolation functionality. The modular approach also enables standardized designs that can be adapted to different situations rather than custom-built centralized transformers.
Solution Approach 2:
The patent creates universal modular transformer units that can be configured in different arrangements to meet various voltage and power requirements. These multi-functional modules provide galvanic isolation across different applications without requiring situation-specific custom designs, reducing device complexity.
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
The solution provides high reliability, efficiency, and cost-effectiveness by optimizing component selection, reducing auxiliary circuits, and avoiding the limitations of centralized transformers, enabling high-voltage conversion with minimal losses and increased adaptability.
Implementation Method 1
a transformer with several magnetic cores (51) through which passes a current loop (64) serving as a primary winding
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a device and a method for reversible DC/DC conversion allowing an exchange of energy between two DC electric networks. This device is asymmetric and comprises several converter modules (70) on the high voltage side, and a converter module (71) on the low voltage side based on a current loop with several magnetic cores.