Clocked Power Supply with Galvanic Isolation and Dynamic Coil Segmentation
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Solution Overview
Problem
Existing power supply units face inefficiencies and increased costs due to the need for oversized components and additional electronics to handle wide input voltage ranges, particularly at higher powers, which leads to heat development and volume issues, and require either voltage switchover or power factor correction circuits that are costly and complex.
Innovation Solution
A power supply unit with galvanic isolation that includes a primary circuit with two switch elements and a voltage evaluation circuit to dynamically switch between them based on input voltage levels, allowing for efficient conversion of alternating or direct input voltage to direct output voltage without the need for complex PFC circuits or voltage multiplication, by adjusting the transformer coil to match input voltage and using a microcontroller for switchover control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the power supply unit is oversized to cover a wide input voltage range, then the voltage range coverage is improved, but the volume and cost increase
Solution Approach 1:
The primary coil is divided into multiple sections with different numbers of winding segments. By selectively activating different sections based on input voltage level, the transformer can adapt to wide voltage ranges without requiring an oversized design. This segmentation allows the same physical transformer to operate efficiently across different voltage conditions.
Solution Approach 2:
The patent implements dynamic switching between different primary coil sections based on detected input voltage levels. A control unit monitors the input voltage and activates the appropriate number of winding segments, allowing the power supply to dynamically adapt its transformation ratio. This dynamic adjustment enables efficient operation across a wide voltage range without oversizing.
2Adaptability or versatility
If additional PFC circuits or voltage multiplication circuits are added, then the input voltage handling capability is improved, but the device complexity and cost increase
Solution Approach 1:
The primary coil serves multiple functions by operating in different configurations. The same coil structure handles both voltage adaptation and power transformation without requiring separate PFC or voltage multiplication circuits. By adjusting the active winding segments, the transformer directly adapts to different input voltages, eliminating the need for additional complexity.
Solution Approach 2:
The patent changes the effective transformation ratio by adjusting the number of active primary winding segments rather than adding complex circuits. This parameter change approach allows the system to handle different input voltages by modifying the electrical characteristics of the existing transformer, avoiding the need for PFC circuits or voltage multiplication stages.
3Adaptability or versatility
If the transformer is oversized to handle voltage variance, then the voltage range coverage is improved, but the efficiency decreases due to increased power loss
Solution Approach 1:
The primary coil is segmented into multiple sections that can be selectively activated. This segmentation allows the transformer to operate with an optimal transformation ratio for each input voltage level, avoiding the inefficiencies associated with oversized transformers operating at reduced loads. Each segment configuration is optimized for specific voltage ranges, maintaining high efficiency across the full input voltage spectrum.
Solution Approach 2:
The effective transformation ratio is dynamically changed by adjusting the number of active primary winding segments. This parameter adjustment ensures that the transformer operates at optimal efficiency points regardless of input voltage variations, preventing the power losses that occur when oversized transformers operate far from their design point.
4Ease of operation
If voltage switchover is implemented, then the direct voltage operation is improved, but the adaptability to alternating voltage is restricted
Solution Approach 1:
The primary coil structure is designed to be universally applicable to both direct and alternating voltage inputs. The same segmented coil configuration that enables direct voltage operation also effectively handles alternating voltage by allowing dynamic adjustment of the transformation ratio. This universal design eliminates the need for separate circuit paths for different input types.
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 solution enables efficient direct voltage operation across a wide input voltage range without the need for complex PFC circuits or voltage multiplication, reducing heat and volume issues while maintaining high efficiency and cost-effectiveness, especially at higher power levels.
Implementation Method 1
a first primary circuit including a series circuit consisting of a primary coil of a transformer
Implementation Method 2
a smoothing capacitor which lies parallel to an output direct voltage of the secondary circuit
Data Source
AI summary
A power supply unit with galvanic isolation for converting an input-side alternating or direct voltage into an output-side direct voltage in a clocked manner, includes a first primary circuit that has a series circuit consisting of a primary coil of a transformer and a first switch element and a first control circuit, at least one secondary circuit that has a secondary coil of the transformer and a smoothing capacitor that is parallel to an output direct voltage of the secondary circuit, a second primary circuit that has a series circuit consisting of a part of the primary coil and a second switch element for pulse length modulation of the voltage at the part of the primary coil, and a voltage evaluator that switches either the first or the second switch element for the next switching cycle depending on the level of the input voltage in order to obviate PFC circuits or a voltage multiplication.