Composite Cascaded HV and LV Modules for Transformer Insulation

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Solution Overview

Problem

Cascaded low-voltage modules face issues with numerous control signals, high cost, and lower power density, while cascaded high-voltage modules struggle with the difficulty of achieving withstand voltages above 6 kV between the primary and secondary sides of a transformer in DC-to-DC modules.

Innovation Solution

A topology of composite cascaded high-voltage and low-voltage modules is introduced, featuring high-voltage and low-voltage modules connected in a cascade manner, with a DC-to-DC module converting low-voltage DC bus voltage into a DC output voltage to power high-voltage and low-voltage driving circuits, reducing the required withstand voltage and improving power density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cascaded low-voltage modules are adopted, then the withstand voltage requirement is easier to meet, but the number of control signals increases, the number of modules increases, cost increases, and power density decreases

Engineering Contradiction:

Improvewithstand voltageVSAvoidnumber of control signals

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system is divided into multiple cascaded low-voltage modules, each operating at a manageable voltage level. This segmentation allows the overall high voltage to be achieved through series connection while keeping individual module complexity low and control signals manageable at each module level.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple low-voltage modules are combined in a cascade configuration to achieve the required high voltage output. The modules work together as an integrated system, with each module contributing to the overall voltage while sharing common control architecture and power supply.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If cascaded low-voltage modules are adopted, then the withstand voltage requirement is easier to meet, but cost increases

Engineering Contradiction:

Improvewithstand voltageVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using a single complex high-voltage module, the design copies the low-voltage module architecture multiple times in a cascade configuration. This allows use of standardized, lower-cost components at each stage while achieving the required overall voltage through replication and series connection.

Inventive Principle:

Principle #26Copying

3Reliability

If cascaded low-voltage modules are adopted, then the withstand voltage requirement is easier to meet, but power density decreases

Engineering Contradiction:

Improvewithstand voltageVSAvoidpower density

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The system dynamically switches between different module combinations and operating modes to optimize power density. By controlling which modules are active and how they are configured, the system maintains high power density while meeting withstand voltage requirements through adaptive cascade operation.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If cascaded high-voltage modules are adopted, then the number of control signals decreases, but the withstand voltage between primary and secondary sides of transformer becomes difficult to achieve above 6 kV

Engineering Contradiction:

Improvenumber of control signalsVSAvoidwithstand voltage

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

A transformer with sufficient insulation rating serves as an intermediary between the high-voltage power conversion stage and the control/low-voltage stages. This intermediary provides the necessary galvanic isolation and voltage transformation, enabling the system to achieve both simplified control and required withstand voltage levels.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively reduces the number of control signals and modules, lowers costs, and simplifies the insulation of transformers by lowering the required withstand voltage, enhancing the efficiency and power density of high-voltage systems.

Implementation Method 1

converting the low-voltage DC bus voltage into a DC output voltage, so as to provide one or more of the at least one high-voltage driving circuit, the at least one low-voltage driving circuit and the at least one local control circuit with a power supply

Methodology Applied

Scientific EffectElectrical energy conversion:

Data Source

PatentUS10148164B2Topology of composite cascaded high-voltage and low-voltage modules

Publication Date: 2018.12.04 DELTA ELECTRONICS (SHANGHAI) CO LTD

AI summary

A topology of composite cascaded high-voltage and low-voltage modules is provided. It includes at least one high-voltage module, at least one low-voltage module, at least one local control circuit and at least one DC-to-DC module. At least one high-voltage module is connected with at least one low-voltage module in cascade manner. At least one local control circuit outputs at least one signal to at least one high-voltage driving circuit and at least one low-voltage driving circuit. An input of at least one DC-to-DC module is connected with two ends of a low-voltage bus capacitor, for receiving a low-voltage DC bus voltage and converting the low-voltage DC bus voltage into a DC output voltage, so as to provide one or more of at least one high-voltage driving circuit, at least one low-voltage driving circuit and at least one local control circuit with a power supply.