DC-DC Converter With Middle-Point Tap For 400V To 800V Range
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Solution Overview
Problem
Current high voltage to low voltage DC-DC converters in reconfigurable vehicle architectures face challenges due to a broad input operating range, particularly when switching between 400V and 800V modes, requiring adaptive stages to efficiently handle these voltage ranges.
Innovation Solution
A DC-DC converter employing a dual active bridge rectifier topology with a transformer having a middle-point tap, allowing current to flow through primary windings in parallel at low voltage and in series at high voltage, enabling efficient conversion across a wide input voltage range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional DC-DC converter is used in reconfigurable vehicle architectures, then it can operate at a single voltage level, but it cannot efficiently handle the broad input operating range when switching between 400V and 800V modes
Solution Approach 1:
The patent implements a dynamic reconfiguration mechanism that switches the primary windings between parallel and series connections based on the operating voltage mode. A controller dynamically controls the switching elements to reconfigure the transformer primary windings, enabling the converter to adapt to both 400V and 800V input voltage ranges using the same hardware platform.
Solution Approach 2:
The patent designs a universal DC-DC converter platform that can operate at multiple voltage levels (both 400V and 800V modes) using the same converter structure. By incorporating reconfigurable primary windings with switching elements, a single converter design serves multiple voltage range requirements, eliminating the need for separate converters for different voltage modes.
2Adaptability or versatility
If adaptive stages are added to handle wide voltage ranges, then voltage range support is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple converters into a single reconfigurable converter. By combining the primary windings into one transformer structure that can be dynamically reconfigured between parallel and series connections, the patent eliminates the need for separate converters for different voltage ranges, thereby reducing overall system complexity while maintaining wide voltage range support.
Solution Approach 2:
The patent segments the primary windings into multiple sections that can be independently connected through switching elements. This segmentation allows flexible reconfiguration of the winding connections (parallel or series) based on the operating mode, enabling wide voltage range support without requiring additional complex adaptive stages.
3Reliability
If multiple converters are used for different voltage modes, then each converter can be optimized for its specific range, but system cost and design time increase
Solution Approach 1:
The patent creates a universal converter platform that maintains optimized performance for both 400V and 800V modes through dynamic reconfiguration. By using a single transformer design with reconfigurable windings and a unified control strategy, the patent achieves mode-specific optimization without requiring separate converters, thereby reducing manufacturing costs and simplifying production.
Solution Approach 2:
The patent changes the electrical parameters of the transformer primary windings dynamically by switching between parallel and series connections. This parameter change allows the same physical transformer to be optimized for different voltage modes, achieving performance optimization equivalent to having separate converters while using a single manufactured unit.
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 provides wide input voltage support with high performance, flexibility, and cost reduction by reusing magnetic design, and only requiring additional power switches during specific operations, enhancing design flexibility and reducing time-to-market.
Implementation Method 1
The transformer is configured to receive the first AC voltage and output a second AC voltage
Data Source
AI summary
A DC-DC converter includes a first switching network that receives an input DC voltage and outputs a first AC voltage, a transformer, and a secondary side conversion circuit. The first switching network receives an input DC voltage. The transformer includes a middle-point primary tap such that when the input DC voltage is in a low voltage range, the middle-point tap of the transformer primary is connected to the input DC voltage causing current to flow through the first plurality of primary windings in parallel to current flowing through the second plurality of primary windings and when the input DC voltage is in a high voltage range, the middle-point tap is disconnected from the input DC voltage causing current to flow through the first plurality of primary windings in series with current flowing through the second plurality of primary windings.