DC-DC Converter Transformer with Segmented Secondary Windings
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Solution Overview
Problem
Existing DC to DC converters with transformers experience significant electromagnetic wave generation and high frequency current components during switching transient periods, leading to wasted capacitive leak currents and inductive surge voltages due to the configuration of secondary windings and rectifying elements.
Innovation Solution
The proposed DC to DC converter incorporates a transformer circuit with four series-connected secondary windings, where the first and second secondary windings are wound in opposite directions around one magnetic path and the third and fourth secondary windings are wound in opposite directions around another magnetic path, along with additional secondary windings and rectifying elements, to reduce high frequency current components and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a transformer with two secondary windings and a full-wave rectifier is used, then current ripples and losses decrease, but high frequency current components and electromagnetic waves are generated during switching transient periods
Solution Approach 1:
The secondary coil is divided into four separate secondary windings (first, second, third, and fourth secondary windings) instead of using two windings. Each winding is connected to a dedicated rectifying element, creating four independent rectification paths. This segmentation allows for more precise control of current flow and reduces the high frequency current components that cause electromagnetic interference during switching transitions.
2Productivity
If secondary windings are configured with rectifying elements to convert AC voltage to DC voltage, then power conversion efficiency improves, but capacitive leak currents and inductive surge voltages increase during switching transitions
Solution Approach 1:
The circuit is segmented into four independent rectification paths, each with its own secondary winding and rectifying element. This segmentation distributes the switching transitions across four separate paths rather than two, reducing the magnitude of current variations and associated harmful effects in each individual path during switching transitions.
3Use of energy by moving object
If a full-wave rectifier with two rectifying elements is used, then both half cycles of AC voltage are utilized, but significant electromagnetic waves are generated during half cycle switching
Solution Approach 1:
The full-wave rectification is achieved through four rectifying elements working in sequence rather than two elements switching between two windings. This creates a smoother transition pattern where four smaller switching events replace two larger switching events, reducing electromagnetic wave generation while maintaining full utilization of both AC voltage half cycles.
Solution Approach 2:
The rectification process is divided into four periodic stages corresponding to the four secondary windings, creating a more frequent but less intense periodic action pattern. This distributes the electromagnetic interference over more frequent, smaller switching events rather than fewer, larger switching events.
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 effectively reduces electromagnetic waves and the impact of current variations on AC impedance components, minimizing leak currents and inductive surge voltages, and splits secondary currents to reduce copper loss and radiation noise.
Implementation Method 1
a transformer circuit including a primary winding and a secondary winding member and configured to convert the AC power applied to the primary winding from the inverter circuit into an output power
Implementation Method 2
The first and second secondary windings are wound around a first magnetic path in opposite directions so as to be electromagnetically coupled to the primary winding
Implementation Method 3
The third and fourth secondary windings are wound around a second magnetic path in opposite directions so as to be electromagnetically coupled to the primary winding
Data Source
AI summary
In a DC to DC converter, a transformer circuit includes a primary winding and a secondary winding member composed of series-connected first to fourth secondary windings having one and the other ends. The one and the other ends of the series-connected first to fourth secondary windings are connected to a first output terminal. The first and second secondary windings are wound around a first magnetic path in opposite directions, and the third and fourth secondary windings are wound around a second magnetic path in opposite directions. A first rectifying element is connected between the second output terminal and a connection point between the first and second secondary windings. A second rectifying element is connected between the second output terminal and a connection point between the third and fourth secondary windings.