Dual-Transformer DC-DC Converter for Wide Output Voltage Range
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Solution Overview
Problem
Conventional LLC resonant converters face challenges in supporting a wide range of output voltage and maintaining constant output power, which affects their efficiency and power density.
Innovation Solution
The proposed apparatus and method utilize a configuration with two transformers and a controller to control current flow patterns, allowing secondary windings to be electrically coupled in series for high voltage output and in parallel for low voltage output, achieving a wide range of output voltage and constant output power without an additional power stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional LLC resonant converter is used, then the structure is simple, but it cannot support a wide range of output voltage and constant output power
Solution Approach 1:
The patent divides the converter into two separate LLC resonant converter modules, each with its own transformer. By controlling the primary windings of the two transformers, the secondary windings can be electrically coupled in series to output high voltage or in parallel to output low voltage, enabling wide output voltage range without adding complex power stages.
Solution Approach 2:
The two transformer modules serve multiple functions: they can operate independently for medium voltage output, couple in series for high voltage output, or couple in parallel for low voltage output. This multi-functionality allows a single converter structure to handle wide output voltage ranges and maintain constant power.
2Adaptability or versatility
If additional power stages are added to expand output voltage range, then the adaptability improves, but the device complexity and component count increase
Solution Approach 1:
The patent dynamically switches between series and parallel coupling configurations of the two transformer secondary windings based on the required output voltage. The controller adjusts the coupling pattern in real-time, allowing the system to adapt to different output voltage requirements without adding fixed power stages.
Solution Approach 2:
The patent merges two LLC resonant converter modules into a single system that shares common control and magnetic components. By combining the secondary windings of both transformers through series or parallel coupling, the system achieves expanded output voltage range without the need for additional power stages or separate conversion paths.
3Device complexity
If the converter structure is simplified, then the device complexity decreases, but the power density and efficiency are reduced
Solution Approach 1:
The patent performs preliminary action by pre-configuring two transformer modules with optimized magnetic components and winding arrangements. This preliminary design allows the system to achieve high power density and efficiency in each module, which are maintained even when the modules are combined through series or parallel coupling to provide wide output voltage range.
4Adaptability or versatility
If the output voltage range is expanded, then the adaptability improves, but the output power stability deteriorates
Solution Approach 1:
The patent employs feedback control to monitor the output voltage and power levels. Based on the detected output conditions, the controller dynamically adjusts the coupling configuration of the two transformer modules and regulates the primary winding currents to maintain constant output power across the wide output voltage range, ensuring power stability.
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 enhances efficiency and power density by optimizing transformer design with fewer components, enabling a wide range of output voltage and constant output power.
Implementation Method 1
a first transformer (102) comprising a first winding (T1A) at a primary side and a second winding (T1B) at a secondary side; a second transformer (104) comprising a third winding (T2A) at a primary side and a fourth winding (T2B) at a secondary side
Data Source
AI summary
Devices and methods for DC-to-DC conversion. The device includes a first transformer having a first winding at a primary side and a second winding at a secondary side. The device also includes a second transformer having a third winding at a primary side and a fourth winding at a secondary side. The device includes a controller configured to control a first current in the first winding of the first transformer and a second current in the third winding of the second transformer to flow in a first pattern, and to control the first current and the second current to flow in a second pattern.