Flyback Controller With Parallel Modules for Bidirectional Battery Testing
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Solution Overview
Problem
Conventional bidirectional DC-DC converters for testing high-power-density secondary batteries are complex and costly due to numerous components, making them difficult to assemble and produce effectively.
Innovation Solution
A flyback controller with parallelly-connected power modules and reduced power devices, utilizing two bidirectional DC-DC converters connected in parallel, along with a digital-signal processor for bidirectional energy flow and transformation, simplifying the structure and increasing power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional phase-shifted full-bridge topology is used, then bidirectional energy flow capability is achieved, but device complexity increases due to numerous power devices
Solution Approach 1:
The conventional full-bridge topology is segmented into two separate bidirectional DC-DC converter modules. Each module contains fewer power devices (two FETs and two diodes per module), making the overall system less complex while maintaining bidirectional capability through parallel operation of the modules
Solution Approach 2:
Each DC-DC converter module is designed to be universally functional in both forward and reverse directions. The same circuit topology and control strategy enable bidirectional energy flow, eliminating the need for separate circuits for each direction and reducing overall device complexity
2Adaptability or versatility
If conventional bidirectional DC-DC converter is used, then large range of current modulation is provided, but manufacturing cost increases due to expansive production requirements
Solution Approach 1:
The system is divided into two identical modular converter units that can be manufactured separately using standardized processes. This segmentation enables mass production of individual modules, reducing per-unit manufacturing costs while maintaining the required current modulation range through parallel operation
Solution Approach 2:
The current modulation range is achieved by varying the duty cycle and switching frequencies of the parallel-connected modules rather than using numerous individual power devices. This parameter-based control approach reduces component count and manufacturing complexity
3Adaptability or versatility
If conventional bidirectional DC-DC converter is used, then bidirectional energy flow is supported, but assembly difficulty increases due to numerous components
Solution Approach 1:
The converter is segmented into two independent modules, each with its own complete set of power devices and control circuitry. This modular design simplifies assembly by allowing each module to be assembled and tested separately before final integration, reducing overall assembly complexity
Solution Approach 2:
Two complete bidirectional converter modules are merged in parallel configuration. Each module is self-contained and functionally complete, allowing for simplified assembly procedures while achieving the combined power output and bidirectional capability required for battery testing applications
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 enables efficient bidirectional energy flow and transformation, reducing assembly and production costs while providing sufficient power output for testing secondary batteries, with improved current control and reduced voltage surges, demonstrating better performance than conventional phase-shifted full-bridge topology converters.
Implementation Method 1
The first inductor is connected in parallel with a primary side. The first inductor is further connected in series with the first capacitor. Opposite to the primary side there is a secondary side. The secondary side is connected in parallel with a second inductor.
Data Source
AI summary
A flyback controller featuring bidirectional power control and parallelly-connected power modules is based on flyback DC-DC converters for allowing bidirectional energy flow and transformation. The flyback controller includes two bidirectional DC-DC converters that are connected in parallel. The bidirectional DC-DC converters are electrically connected with a digital-signal processor. The digital-signal processor controls the bidirectional DC-DC converters and current thereof, so that the current flows evenly across the bidirectional DC-DC converters. Thereby, the flyback controller has advantages about simplified components and increased power output, and is suitable for testing secondary batteries.