DC/DC Converter Autotransformer Current Doubler Topology
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Solution Overview
Problem
Current DC/DC converters face challenges in achieving high efficiency and power density simultaneously, with issues related to thermal distribution, AC ripple on output capacitors, voltage and current stress, and the need for increased components like semiconductors and magnetic components.
Innovation Solution
The secondary side of the DC/DC converter incorporates an autotransformer with a common center tap acting as a current doubler, and two transformers connected in series on the primary side, along with rectifying switching devices, to reduce current and voltage stress, and allow for parallel or series connections of converters for improved efficiency and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If resonant converters are used to achieve high efficiency, then efficiency is improved, but the high AC-current of the output filter results in high power losses and large volume
Solution Approach 1:
The patent divides the single resonant converter into multiple parallel resonant converters. Each converter handles a portion of the total power, which reduces the AC current through individual output filters. This segmentation allows for smaller, more efficient filters while maintaining high overall efficiency through soft-switching operation in each parallel unit.
Solution Approach 2:
The patent combines multiple resonant converters in parallel configuration to achieve high power output while maintaining efficiency. By merging multiple units with phase-staggering control, the system achieves both high efficiency (from resonant operation) and reduced power losses (from distributed current handling), resolving the contradiction between efficiency and power loss.
2Power
If two or more resonant converters are placed in series and/or parallel to increase DC power, then power output is improved, but the complexity of control and synchronization increases
Solution Approach 1:
The patent employs phase-staggering control where multiple resonant converters operate with deliberate phase shifts between their switching cycles. This periodic action with controlled phase differences allows the converters to be synchronized naturally, reducing control complexity while enabling high power output through series and parallel configurations.
Solution Approach 2:
The patent implements control mechanisms that monitor and adjust the operation of parallel resonant converters to maintain synchronization and optimal performance. Through feedback control of switching phases and operating parameters, the system manages multiple converters with reduced complexity while achieving high DC power output.
3Loss of energy
If the number of semiconductors and magnetic components is increased to achieve high efficiency, then efficiency is improved, but power density decreases
Solution Approach 1:
The patent segments the power conversion function across multiple parallel resonant converters, each using fewer semiconductor and magnetic components. This segmentation maintains high efficiency through resonant soft-switching in each unit while distributing the total component count, thereby preserving power density that would otherwise be reduced by concentrating all components in a single high-efficiency converter.
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 configuration achieves high efficiency and power density while reducing component stress and complexity, improving thermal distribution, and minimizing the number of capacitors needed, resulting in a more reliable and compact converter system.
Implementation Method 1
an autotransformer consisting of a first and a second winding connected to a common center tap, which autotransformer is adapted to act as a current doubler
Implementation Method 2
The primary side consisting of a resonant converter, which converter comprises at least one transformer
Data Source
AI summary
The present invention relates to a DC/DC converter (1) with primary side (11) consisting of a resonant converter, which DC/DC converter (1) comprises a first and a second transformer (T1, T2), connected in series on the primary side (11) and on the secondary side (12) of the DC/DC converter. The secondary side (12) comprises an autotransformer (Tcd) consisting of a first and a second winding (Tcda, Tcdb) connected to a common center tap (Tcdc), where the first winding (Tcda) of the autotransformer (Tcd) is connected to the secondary winding (T1b) of the first transformer (T1), forming a first output connection point (P1), the second winding (Tcdb) of the autotransformer (Tcd) is connected to the secondary winding (T2b) of the second transformer (T2), forming a second output connection point (P2).