DC/DC Converter Mode Switching for Wide Input Voltage Stability
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Solution Overview
Problem
Conventional DC/DC converters face issues with large volume, high cost, and reduced efficiency due to the need for two-stage conversion circuits and additional components, which require restarting when input voltage changes, leading to unstable output voltage and increased power loss.
Innovation Solution
A DC/DC converter with a switching circuit that can dynamically switch between full-bridge and half-bridge modes, using an asymmetric half-bridge circuit topology and controlled duty cycles to maintain stable operation, reducing the need for additional components and minimizing power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two-stage conversion circuits are used to achieve wide input voltage range, then the voltage range is improved, but the volume and cost increase
Solution Approach 1:
The patent applies dynamic mode switching between full-bridge and half-bridge configurations based on real-time input voltage detection. The controller dynamically adjusts the switching pattern of bridge arms, enabling the converter to adapt to wide input voltage ranges (e.g., 100V-380V) without physical reconfiguration, thereby achieving versatility without increasing volume.
Solution Approach 2:
The patent makes a single bridge circuit perform multiple functions by switching between full-bridge mode (for high voltage input) and half-bridge mode (for low voltage input). This multi-functionality eliminates the need for separate two-stage conversion circuits, reducing both volume and cost while maintaining wide input voltage adaptability.
2Adaptability or versatility
If two-stage conversion circuits are used to achieve wide input voltage range, then the voltage range is improved, but the cost increases
Solution Approach 1:
The patent makes a single bridge circuit perform multiple functions by switching between full-bridge mode (for high voltage input) and half-bridge mode (for low voltage input). This multi-functionality eliminates the need for separate two-stage conversion circuits, reducing both volume and cost while maintaining wide input voltage adaptability.
3Device complexity
If the operation mode is fixed and cannot be dynamically switched, then the device complexity is reduced, but the output voltage stability deteriorates when input voltage changes
Solution Approach 1:
The patent implements dynamic mode switching where the controller continuously monitors input voltage and automatically transitions between full-bridge and half-bridge modes. This dynamic adaptation maintains optimal conversion ratios across varying input conditions, ensuring output voltage stability without requiring complex manual reconfiguration.
Solution Approach 2:
The patent employs feedback control where the controller detects input voltage changes and adjusts the switching mode accordingly. The feedback mechanism ensures that the converter automatically compensates for input voltage variations, maintaining stable output voltage while managing the complexity through intelligent control algorithms.
4Adaptability or versatility
If additional switching elements and voltage-divider capacitors are added to achieve symmetric half-bridge topology, then the circuit functionality is improved, but the volume and cost increase
Solution Approach 1:
The patent employs asymmetric half-bridge topology where the two bridge arms have unequal configurations. One arm operates with active switching elements while the other arm uses passive components or simplified switching. This asymmetric design achieves the necessary half-bridge functionality without requiring additional symmetric components, thereby reducing volume and cost.
5Adaptability or versatility
If additional switching elements are added to achieve symmetric half-bridge topology, then the circuit functionality is improved, but the power loss increases and efficiency decreases
Solution Approach 1:
The patent employs asymmetric half-bridge topology where the two bridge arms have unequal configurations. One arm operates with active switching elements while the other arm uses passive components or simplified switching. This asymmetric design achieves the necessary half-bridge functionality without requiring additional symmetric components, thereby reducing volume and cost.
Solution Approach 2:
The patent extracts or removes unnecessary switching elements from the traditional symmetric half-bridge configuration. By eliminating redundant components that contribute to power loss, the patent achieves half-bridge functionality with reduced component count, lower power consumption, and improved efficiency.
6Adaptability or versatility
If the converter is disabled and restarted when input voltage changes, then the operation mode can be adjusted, but the productivity and response time deteriorate
Solution Approach 1:
The patent implements dynamic mode switching where the controller continuously monitors input voltage and automatically transitions between full-bridge and half-bridge modes. This dynamic adaptation maintains optimal conversion ratios across varying input conditions, ensuring output voltage stability without requiring complex manual reconfiguration.
Solution Approach 2:
The patent ensures continuous operation without disabling or restarting the converter when input voltage changes. The seamless transition between operating modes maintains uninterrupted power conversion, improving productivity and response time while adapting to varying input conditions.
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 solution achieves a smaller volume, lower cost, and higher efficiency by allowing seamless voltage range adaptation without restarting, reducing transformer saturation risks and power loss, and stabilizing output voltage.
Implementation Method 1
a transformer T1 having a primary winding Np and a secondary winding Ns
Data Source
AI summary
A DC/DC converter includes a switching circuit and a capacitor. The switching circuit includes a first bridge arm and a second bridge arm connected in parallel. The first bridge arm includes a first switch and a second switch. The second bridge arm includes a third switch and a fourth switch. The capacitor is electrically connected with a node between the first switch and the second switch. While the switching circuit is switched from a half-bridge mode to a full-bridge mode, the duty cycle of the control signal for controlling the fourth switch is gradually decreased from 100% to be synchronized with the duty cycle of the control signal for controlling the first switch. Then, the duty cycle of the control signal for controlling the third switch is gradually increased from zero to be synchronized with the duty cycle of the control signal for controlling the second switch.