DC-DC Auto-Converter Module for High Voltage Ratio Efficiency
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Solution Overview
Problem
Conventional DC-DC converters face limitations in efficiency and power capability, particularly when dealing with large voltage ratios, leading to increased size, weight, and cost for the same power level.
Innovation Solution
The introduction of auto-converter technology, which reconfigures existing DC-DC converters by galvanically connecting certain terminals to form non-isolated configurations, enhancing efficiency and power capability through unique wiring arrangements that allow for higher power throughput and reduced losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional DC-DC converter topologies are used, then basic voltage conversion is achieved, but efficiency decreases and power capability is limited when dealing with large voltage ratios
Solution Approach 1:
The converter is divided into multiple modular units (first DC-DC converter, second DC-DC converter, third DC-DC converter) that can be independently configured. Each module handles a portion of the voltage conversion task, allowing the system to efficiently manage large overall voltage ratios by combining multiple smaller conversion stages with optimized duty cycles.
Solution Approach 2:
The system dynamically switches between different converter configurations (isolated and non-isolated modes) based on operating conditions. The controllers adjust the operational mode and duty cycles in real-time to optimize efficiency for the current voltage ratio and power level, adapting to varying load and input voltage conditions.
2Power
If converter power capability is increased to handle higher power levels, then power throughput improves, but size, weight, and cost increase
Solution Approach 1:
The same converter modules and components are used across multiple configurations and power levels. The standardized modular design allows a single component library to serve multiple functions and power ratings, reducing the need for additional specialized components when scaling power capability, thereby controlling weight and cost increases.
Solution Approach 2:
Multiple converter modules are combined in parallel or series configurations to achieve higher power ratings. By merging standard modules rather than designing a completely new high-power converter, the system achieves increased power capability while minimizing the weight increase that would result from a monolithic high-power design.
3Reliability
If isolated converter configuration is used, then galvanic isolation is provided, but efficiency and power capability decrease compared to non-isolated configurations
Solution Approach 1:
The system dynamically selects between isolated and non-isolated configurations based on the specific application requirements and operating conditions. The controller can switch between modes to optimize for either isolation (when reliability is paramount) or efficiency (when power loss must be minimized), providing the best performance for each scenario.
Solution Approach 2:
The patent introduces intermediate coupling mechanisms that allow the system to achieve both isolation and high efficiency. By using controlled switching and intermediate energy storage elements, the system can provide galvanic isolation when needed while maintaining efficiency through optimized power transfer paths, effectively mediating between the two conflicting requirements.
Data Source
AI summary
A DC-DC auto-converter module includes a positive source terminal, a negative source terminal, a positive load terminal, a negative load terminal, and a DC-DC converter. The negative source terminal cooperates with the positive source terminal to facilitate electrical connection of a DC power source thereto. The negative load terminal cooperates with the positive load terminal to facilitate connection of an electrical load thereto. The isolated DC-DC converter comprises an input circuit and an output circuit that is galvanically isolated from the input circuit. The DC-DC converter includes a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. At least one of the positive input terminal, the negative input terminal, the positive output terminal, and the negative output terminal is galvanically connected to at least one of the positive source terminal, the negative source terminal, the positive load terminal, and the negative load terminal.