Bidirectional DC-DC Converters with Partial Energy Processing
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Solution Overview
Problem
Existing DC-to-DC converters are inefficient and have a limited adjustment range for higher voltage applications, requiring larger devices to maintain voltage and withstand high power or currents, particularly in electric vehicles and shipboard power systems.
Innovation Solution
The proposed solution involves bidirectional DC-to-DC converter architectures with partial energy processing, utilizing separate majority and minority power paths, low Rdson Gallium Nitride (GaN) devices, high operation frequency, magnetic integration, and rotation control to enhance efficiency and power density, along with simplified control schemes and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional DC-to-DC converter architectures are used for higher voltage applications, then voltage regulation can be maintained, but device size increases and efficiency decreases
Solution Approach 1:
The converter is divided into multiple power modules (first power module, second power module, third power module) that can operate independently or in combination. This segmentation allows the system to handle higher voltages and powers without requiring a single large converter, thereby improving efficiency while avoiding excessive size increase.
Solution Approach 2:
The patent employs partial energy processing where not all power modules need to operate at full capacity simultaneously. The system can dynamically activate only the necessary number of modules based on load requirements, reducing overall device size while maintaining efficiency during partial load operations.
2Reliability
If larger devices are used to withstand high power or currents in higher voltage applications, then voltage maintenance is improved, but device complexity and size increase
Solution Approach 1:
The converter architecture is segmented into multiple standardized power modules with similar structures. Each module contains switching elements, inductors, and capacitors arranged in a consistent configuration. This modular segmentation maintains reliability through redundancy and load distribution while controlling complexity through standardization.
Solution Approach 2:
Each power module is designed to be universal and can perform multiple functions - handling different voltage levels, power levels, and operating conditions. The modules can be configured in series for high voltage, parallel for high current, or combinations thereof, providing multi-functionality that maintains reliability across diverse operating scenarios without requiring separate specialized circuits.
3Adaptability or versatility
If conventional converter designs are used for higher voltage applications, then basic conversion function is achieved, but adjustment range is limited
Solution Approach 1:
The converter employs dynamic control of multiple power modules where the system can adaptively switch between different module configurations based on real-time operating conditions. The control circuitry dynamically adjusts which modules are active and how they are connected, enabling a wide voltage adjustment range while maintaining optimal efficiency across different operating points by selecting the most efficient configuration for each condition.
Solution Approach 2:
The system changes operational parameters by varying the number of active power modules and their connection topology. By dynamically changing parameters such as the effective turns ratio (through series/parallel module configuration) and switching frequencies, the converter achieves wide voltage adjustment range while maintaining high efficiency through optimal parameter selection for each operating condition.
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 approach enables more efficient power transfer, wider voltage regulation, and improved thermal performance, reducing the size of transformers and increasing power density, thus addressing the inefficiencies and limited adjustment range of traditional converters.
Implementation Method 1
A transformer, or multiple transformers, can be used to transform the AC voltage into a majority AC voltage of a majority power path and a minority AC voltage of a minority power path
Data Source
AI summary
Aspects of bidirectional architectures with partial energy processing in resonant direct current (DC)-to-DC converters are described. In one embodiment, an alternating circuit (AC)-to-DC circuit generates an AC voltage from a DC voltage. A voltage of the AC voltage is transformed into a majority AC voltage of a majority power path and at least one minority AC voltage of the minority power paths. The majority AC voltage is rectified into a majority DC voltage and a minority AC voltage is rectified into a minority DC voltage. The majority power path and the minority power path are combined as a combined DC voltage.