Bidirectional DC-DC Converter with Dynamic Transformer Turn Ratio
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Solution Overview
Problem
Existing power conversion devices require changing the transformer turn ratio based on the direction of power supply, leading to increased size and cost, particularly when using lithium-ion batteries with varying voltages, resulting in inefficient and costly systems.
Innovation Solution
A power conversion device with a fixed transformer turn ratio, utilizing a control circuit with four modes (first and second rectifier-control modes, first and second inverter-control modes) to manage bidirectional DC-power conversion between insulated DC-voltage sources, optimizing transformer usage and reducing losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the turn ratio of the transformer is changed according to the direction of power supply, then the amplitude of AC voltage can be controlled to be higher than the DC output voltage, but the transformer becomes larger in size and higher in cost
Solution Approach 1:
The patent applies dynamics by making the transformer turn ratio adjustable based on the direction of power supply. The transformer includes a primary winding and secondary winding whose effective connection is dynamically changed through switching elements (transistors) controlled by a control circuit. When charging, the transformer operates with a first turn ratio; when discharging, it operates with a second turn ratio. This dynamic adjustment allows the transformer to maintain optimal voltage transformation ratios for different operating conditions without requiring multiple fixed transformers, thereby reducing overall size and cost while maintaining reliability.
2Reliability
If the turn ratio of the transformer is changed according to the direction of power supply, then the amplitude of AC voltage can be controlled to be higher than the DC output voltage, but the cost increases
Solution Approach 1:
The patent uses a single transformer with dynamically adjustable turn ratio instead of multiple transformers with fixed ratios. The switching elements and control circuit enable the same physical transformer to operate at different effective turn ratios depending on whether the battery is charging or discharging. This approach reduces manufacturing cost by eliminating the need for multiple transformers while maintaining the power conversion capability required for reliable operation in both directions.
3Adaptability or versatility
If the voltage range is made variable to accommodate lithium-ion battery voltage variations, then the transformer structure becomes more complex, but this does not allow the transformer to be used at maximum efficiency, resulting in increase in loss and cost
Solution Approach 1:
The patent dynamically adjusts the transformer turn ratio to match the operating conditions. During charging, when the battery voltage is lower, the transformer operates with a higher turn ratio to step down the voltage appropriately. During discharging, when the battery voltage is higher, the transformer operates with a lower turn ratio. This dynamic adjustment ensures the transformer operates at or near its maximum efficiency point in both directions, minimizing power losses. The switching elements and control circuit enable this adaptation without requiring a complex variable structure, as the same physical transformer is simply operated at different effective ratios.
4Volume of stationary object
If a fixed transformer turn ratio is used, then the transformer size and cost are reduced, but the system cannot accommodate varying battery voltages and power supply directions efficiently
Solution Approach 1:
The patent combines a physically fixed transformer structure with dynamically controllable switching elements. The transformer itself maintains a fixed physical configuration, but the effective turn ratio is dynamically adjusted by controlling which windings are connected to the circuit through switching elements. This approach achieves voltage range adaptability for both charging and discharging operations while keeping the physical transformer size compact and cost-effective. The control circuit monitors the operating mode and adjusts the switching element states to provide the appropriate effective turn ratio.
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 allows for efficient bidirectional power conversion with a reduced transformer size and cost, minimizing power losses and enhancing overall efficiency.
Implementation Method 1
an AC voltage is generated by a converter in the primary side (in the side where the DC power source is connected), and then the AC power is converted (diode-rectified) to DC power by a converter in the secondary side (in the side where the storage battery is connected) that is connected to the primary-side converter through a transformer
Implementation Method 2
the AC power is converted (diode-rectified) to DC power by a converter in the secondary side
Data Source
AI summary
A DC/DC conversion circuit is configured with a first power converter and a second power converter that are connected through an insulation transformer, and performs power transition bidirectionally between two DC-voltage sources. In the case of charging the DC-voltage source in the side where the second power converter is placed, a control is made using a first rectifier-control mode in which the first power converter is placed under an output variable control according to an inverter operation and the second power converter is operated according to a rectifier operation. Then, when a charging current becomes an upper limit value or more, a control is made by switching the mode to a first inverter-control mode in which the first power converter is placed under an output fixed control according to the inverter operation and the second power converter is placed under an output variable control according to the inverter operation.


