Electronic-Embedded Transformer Current Sharing in Parallel DCX Converters
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Solution Overview
Problem
Current SRC-based DCX converters face challenges in paralleling transformers due to current-sharing issues caused by small tolerances in resonant tanks, leading to inefficiencies and limited power handling capacity and power density.
Innovation Solution
The implementation of electronic-embedded transformers (EETs) with electronically-controlled or electronically-coupled resonant capacitors in a bridge configuration, which provide better current sharing and load-independent voltage gain by canceling leakage inductance through phase-shifted control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional transformers are paralleled to increase power handling capacity, then power handling capacity increases, but current sharing becomes unequal due to tolerances in resonant tanks
Solution Approach 1:
The patent implements an electronic control system that senses the current through each paralleled transformer winding and uses feedback signals to adjust the switching timing of electronic switches. This feedback mechanism dynamically compensates for manufacturing tolerances in resonant tanks, ensuring equal current distribution among paralleled transformers while maintaining high power handling capacity
Solution Approach 2:
The patent transforms the static transformer paralleling problem into a dynamic control problem by introducing electronically controlled switches and phase-shifted control signals. The system continuously adjusts switching parameters based on real-time current measurements, enabling adaptive current sharing that maintains equality despite variations in resonant tank characteristics
2Power
If conventional transformers are paralleled to increase power density, then power density increases, but efficiency decreases due to current sharing issues
Solution Approach 1:
The electronic control system monitors current distribution and provides feedback to adjust switching timing, ensuring optimal current sharing among paralleled transformers. This minimizes circulating currents and reduces energy losses, maintaining high conversion efficiency while achieving increased power density through parallel configuration
Solution Approach 2:
The patent dynamically changes switching parameters including phase shift angles and timing offsets based on real-time operating conditions. By adjusting these parameters, the system optimizes current distribution and minimizes energy losses, enabling high power density operation with maintained efficiency
3Manufacturing precision
If electronically-controlled resonant capacitors are added to create EETs, then current sharing and voltage gain improve, but device complexity increases
Solution Approach 1:
The electronic control system serves multiple functions simultaneously: it controls the switching of resonant capacitors, regulates current sharing among paralleled transformers, maintains voltage gain, and provides protection functions. This multi-functionality reduces the need for separate control circuits and minimizes overall system complexity despite adding electronic components
Solution Approach 2:
The patent merges the resonant capacitor control function with the existing transformer structure by integrating electronic switches directly into the transformer circuitry. The control signals for resonant capacitors are combined with the main switching control, creating a unified control architecture that manages both functions through a single control system
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
EETs enhance current sharing among paralleled transformers, enabling higher power handling capacity and power density while maintaining high efficiency and load-independent voltage gain, addressing the limitations of conventional transformer paralleling.
Implementation Method 1
electronically-controlled or electronically-coupled resonant capacitors in a bridge configuration, which provide better current sharing and load-independent voltage gain by canceling leakage inductance through phase-shifted control signals
Data Source
AI summary
Power converters including electronic-embedded transformers for current sharing and load-independent voltage gain are described. In one example, a power converter system includes an input, an output, a power converter between the input and output, and a controller. The converter includes a first bridge, a second bridge, and an electronic-embedded transformer (EET) between the first and second bridge. The EET includes a capacitor and a capacitance coupling switch bridge. The controller generates switching control signals for the first and second bridges and phasing drive control signals for the capacitance coupling switch bridge in the EET. The controller applies a phase shift to the phasing drive control signals for the EET as compared to the switching control signals for the first and second bridges, so that the voltage across the capacitor in the EET cancels the leakage inductance of the transformer windings in the EET, at any switching frequency.