DC to DC Converter with Segmented Transformer Taps
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Solution Overview
Problem
Existing DC to DC converters, such as LLC resonant converters, face performance degradation when the output voltage deviates from the rated output voltage, leading to increased complexity, cost, and power loss due to the need for additional components like bidirectional blocking power switches to achieve multiple DC output voltage levels.
Innovation Solution
A DC to DC converter design that incorporates a transformer with intermediate AC conversion, utilizing a primary and secondary winding with specific tap arrangements and power switches to achieve two or three-level DC output voltage without the need for additional bidirectional switches, thereby reducing power loss and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional bidirectional blocking power switches are included to achieve multiple DC output voltage levels, then the number of DC output voltage levels increases, but power loss, cost and complexity increase
Solution Approach 1:
The patent divides the secondary winding into multiple segments with different tap points (first tap, second tap, third tap, fourth tap) arranged in sequence. Each tap point provides a different voltage level, allowing the converter to achieve multiple DC output voltage levels through segmented winding structure rather than adding complex switching components.
Solution Approach 2:
The patent introduces a clamping circuit as an intermediary component that includes a clamping switch and clamping capacitor. This clamping circuit acts as a mediator to generate artificial neutral points and enable multiple voltage levels without requiring additional bidirectional blocking power switches, thereby reducing complexity while maintaining adaptability.
2Adaptability or versatility
If additional bidirectional blocking power switches are included to achieve multiple DC output voltage levels, then the number of DC output voltage levels increases, but power loss increases
Solution Approach 1:
The patent divides the secondary winding into multiple segments with different tap points (first tap, second tap, third tap, fourth tap) arranged in sequence. Each tap point provides a different voltage level, allowing the converter to achieve multiple DC output voltage levels through segmented winding structure rather than adding complex switching components.
Solution Approach 2:
The patent introduces a clamping circuit as an intermediary component that includes a clamping switch and clamping capacitor. This clamping circuit acts as a mediator to generate artificial neutral points and enable multiple voltage levels without requiring additional bidirectional blocking power switches, thereby reducing complexity while maintaining adaptability.
3Loss of energy
If resonant converter operates at higher frequencies to reduce switching losses, then switching losses decrease, but output voltage adjustment capability deteriorates when far from rated output voltage
Solution Approach 1:
The patent divides the secondary winding into multiple segments with different tap points (first tap, second tap, third tap, fourth tap) arranged in sequence. Each tap point provides a different voltage level, allowing the converter to achieve multiple DC output voltage levels through segmented winding structure rather than adding complex switching components.
Solution Approach 2:
The patent implements dynamic voltage adjustment by enabling the converter to switch between multiple fixed voltage levels (first, second, third, and fourth voltage levels) corresponding to different tap points. This dynamic switching capability allows the system to adapt to different output voltage requirements while maintaining optimal resonant operation.
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 design allows for efficient adjustment of DC output voltage between two or three levels using fewer power switches, decreasing cost and complexity while minimizing power loss, and maintaining performance across a wider range of output voltages.
Implementation Method 1
a transformer having a primary winding and a secondary winding
Implementation Method 2
a first DC to AC conversion circuit having its AC terminals coupled with the primary winding of the transformer
Implementation Method 3
a first AC to DC conversion circuit having its AC terminals coupled across a first tap and a second tap of the secondary winding
Data Source
AI summary
A DC to DC converter with intermediate conversion into AC power, including: a transformer having a primary winding and a secondary winding; a first DC to AC conversion circuit having its AC terminals coupled with the primary winding of the transformer; a first AC to DC conversion circuit having its AC terminals coupled across a first tap and a second tap of the secondary winding of the transformer; a second AC to DC conversion circuit having its AC terminals coupled across a third tap and a fourth tap of the secondary winding of the transformer, wherein the first tap and the second tap are arranged between the third tap and the fourth tap along the secondary winding of the transformer; and at least one first power switch, being arranged between one of DC terminals of the first AC to DC conversion circuit and one of DC terminals of the second AC to DC conversion circuit. By having the solution as above, the DC output voltage may be changed between two levels by operating only one power switch. Because a power switch is more expensive than a multiple of power diodes, by reducing the number of power switches responsible for changing the level of DC output voltage, it is helpful for decreasing the cost and complexity of control. Besides, the power loss can be decreased due to switching of less power switch.