DC-DC Converter Wide Voltage Utilization
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Solution Overview
Problem
Existing DC-DC power conversion systems have limited voltage utilization ratios, which restrict their ability to accommodate variable input voltages from energy harvesting sources like photovoltaic cells and wind turbines, leading to inefficiencies and in-rush current transients during start-up that degrade system performance.
Innovation Solution
A DC-DC power converter design with a pair of upper and lower switches connected in series, along with output capacitors and inductors, allows for wide voltage utilization by switching duty cycles to maintain output voltage set points across varying input voltages, and includes a controller for pulse-width modulation and pre-charge boost mode to mitigate in-rush currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a DC-DC power converter uses a conventional single-switch topology, then the device complexity is low, but the voltage utilization ratio is limited to approximately 3:1
Solution Approach 1:
The power converter circuit is segmented into multiple independent switching modules (first switching module with first and second switches, second switching module with third and fourth switches). Each module can operate independently or in combination, enabling the system to handle a broader range of input voltages through modular configuration rather than requiring a completely different circuit topology for each voltage level.
Solution Approach 2:
The patent transitions from a single-dimensional switching approach (one switch controlling one voltage level) to a multi-dimensional switching architecture where multiple switches operate in coordinated sequences. This allows the system to access multiple voltage levels (Vdc1, Vdc2, Vdc1+Vdc2) by combining different switch configurations, effectively adding a dimensional aspect to voltage control.
2Adaptability or versatility
If the power converter operates with variable input voltages from energy harvesting sources, then the adaptability to different energy sources is improved, but in-rush current transients occur during start-up that degrade system performance
Solution Approach 1:
The patent implements a pre-charge boost mode that activates before normal operation begins. During this preliminary phase, the switching circuit configures itself to gradually charge the output capacitor, preventing the sudden in-rush current that would otherwise occur when full power is applied. This preliminary action protects the system components while maintaining adaptability to variable input voltages from different energy harvesting sources.
3Productivity
If the voltage utilization ratio is increased to accommodate wider input voltage ranges, then the power production efficiency is improved, but the control complexity increases due to multiple switching states
Solution Approach 1:
The control system dynamically adjusts switching patterns based on real-time detection of input voltage levels. The controller monitors the actual voltage from energy harvesting sources and automatically selects the appropriate switching configuration (single switch module active, both modules active, specific switch combinations) without requiring manual intervention or complex predetermined control logic for each voltage scenario.
Solution Approach 2:
The system incorporates feedback mechanisms where the controller continuously monitors input voltage levels and adjusts switching states accordingly. This feedback loop enables the control system to maintain optimal power conversion efficiency across wide voltage ranges by automatically adapting the switching configuration to match the current input conditions, thereby managing control complexity through intelligent response rather than rigid pre-programming.
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
The system achieves wider voltage utilization ratios, enhancing power production efficiency and extending component lifespan by reducing in-rush currents during start-up, while maintaining stable output voltage across variable input conditions.
Implementation Method 1
A DC-DC power converter design with a pair of upper and lower switches connected in series, along with output capacitors and inductors, allows for wide voltage utilization by switching duty cycles to maintain output voltage set points across varying input voltages
Implementation Method 2
A DC-DC power converter design with a pair of upper and lower switches connected in series, along with output capacitors and inductors
Implementation Method 3
A DC-DC power converter design with a pair of upper and lower switches connected in series, along with output capacitors and inductors
Implementation Method 4
includes a controller for pulse-width modulation and pre-charge boost mode to mitigate in-rush currents
Data Source
AI summary
A DC-DC power converter comprises: first, second and third input nodes for connection to one or more DC input power sources; a pair of upper switches TH1, TH2 connected in series between the first and second input nodes; and a pair of lower switches TL1, TL2 connected in series between the second and third input nodes. An output port is connected, via one or more output capacitors and one or more output inductors, to an upper switching node between the pair of upper switches and a lower switching node between the pair of lower switches TL1, TL2. The converter is connectable to a pair of DC input power sources, with a first DC input power source connected between the first and second input nodes and a second DC input power source connected between the second and third input nodes, and, when so connected, the pair of upper switches TH1, TH2 and the pair of lower switches TL1, TL2 are switchable to provide DC output power at the output por. The converter is connectable to one DC input power source connected between the first and third input nodes, and, when so connected, the pair of upper switches TH1, TH2 and the pair of lower switches TL1, TL2 are switchable to provide DC output power at the output port.