Branched Resonant Converter Topology for Multi-Module Output Control
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Solution Overview
Problem
Existing LLC resonant converters face challenges in high power applications due to significant power loss, thermal issues, and the risk of shorts leading to fire hazards, particularly in branched configurations where current density is high, and the master-slave feedback concept breaks down when using a branched tank topology.
Innovation Solution
A resonant converter circuit with a branched resonant tank topology, where the resonant inductor network is split into parallel branches with series and parallel inductors, reducing current density and optimizing power delivery, and a controller system that adjusts the switching frequency based on feedback signals to maintain consistent output across multiple output modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a branched resonant tank topology is used to distribute current and reduce fire hazard risk, then safety and reliability are improved, but the master-slave feedback control breaks down and output consistency deteriorates
Solution Approach 1:
The resonant tank is segmented into multiple independent parallel branches, each with its own series inductor and parallel inductor. This segmentation distributes current across branches, reducing current density and fire hazard risk while maintaining individual branch independence that enables separate feedback control paths
Solution Approach 2:
Feedback signals are obtained from each output module and fed to the controller, which adjusts switching frequency based on these feedback signals. This ensures output consistency across bulk modules despite the branched topology, resolving the feedback control breakdown issue
2Loss of energy
If the resonant inductor network is split into parallel branches, then current density is reduced and power loss decreases, but device complexity increases
Solution Approach 1:
The single resonant inductor network is segmented into multiple parallel branches, each containing series and parallel inductors. This segmentation reduces current density in each branch, thereby reducing power loss while the modular structure makes the complexity manageable
Solution Approach 2:
Each branch in the parallel resonant tank serves multiple functions: it provides resonant inductance, distributes current to reduce power loss, and enables independent feedback control. This multi-functionality justifies the increased structural complexity by delivering multiple benefits from the same structural element
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 branched resonant tank topology reduces the risk of fire hazards and power losses by distributing current density, while the controller system ensures consistent output across bulk modules, optimizing efficiency and minimizing cross-regulation between branches.
Implementation Method 1
the resonant inductor network is split into parallel branches with series and parallel inductors, reducing current density
Implementation Method 2
significant power loss, thermal challenges
Implementation Method 3
LLC resonant converters are power supply devices that convert a DC input into an AC output
Implementation Method 4
The LLC tank filters the input square wave and generates a sinusoidal output current
Implementation Method 5
a controller system that adjusts the switching frequency based on feedback signals to maintain consistent output
Data Source
AI summary
This disclosure describes systems, methods, and apparatus for controlling a voltage provided to a plurality of configurable output modules using a resonant converter, the resonant converter comprising: an inverter circuit; a resonant capacitor bridge coupled across the inverter circuit; N groups of output modules, each of the N groups comprising terminals configured for coupling to up to M output modules, the output modules each comprising: a transformer having a primary and a secondary; and a rectified output coupled to the secondary and configured for coupling to a load; and a resonant inductor network configured to be coupled between the resonant capacitor bridge and the primaries of the transformers, the resonant inductor network comprising: at least one parallel inductor; and N parallel branches arranged in parallel and each branch comprising a series inductor, each of the series inductors configured for transformer-coupling to up to M output modules.