Flyback Converter Transformer with Voltage-Adaptive Winding Segmentation
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Solution Overview
Problem
Existing flyback converters are limited in their ability to maintain efficiency and control behavior across a wide range of input voltage ratios, requiring larger, more expensive components and limited to specific voltage ranges due to fixed mark-to-space ratios.
Innovation Solution
A transformer with multiple winding areas and a voltage monitoring unit that adjusts the storage capacity based on primary voltage, allowing automatic input voltage range switching and varying transmission ratios, enabling connection to different winding areas depending on voltage levels and using a clock control unit to influence the transmission ratio through a mark-to-space ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flyback converter is designed for a wide input voltage range, then adaptability is improved, but device complexity increases due to multiple winding areas and voltage monitoring requirements
Solution Approach 1:
The transformer primary winding is divided into multiple winding areas (first winding area and second winding area) with different turn ratios. The voltage monitoring unit selectively connects the voltage input to different winding areas based on the detected primary voltage level, enabling the converter to adapt to wide input voltage ranges while maintaining manageable transformer structure through systematic segmentation.
Solution Approach 2:
The transformer configuration is made dynamic through the voltage monitoring unit that automatically switches between different winding areas based on real-time voltage detection. This dynamic reconfiguration allows the transmission ratio to vary with input voltage conditions, providing adaptability without requiring multiple fixed transformers.
2Reliability
If components are dimensioned for higher performance to handle larger voltage ratios, then reliability is improved, but cost increases
Solution Approach 1:
Different winding areas are designed with specific local characteristics optimized for their intended voltage range. The first winding area handles higher voltages with appropriate insulation and turn ratios, while the second winding area handles lower voltages. This local optimization allows each component to be designed for its specific operating conditions rather than over-engineering all components for maximum voltage handling.
Solution Approach 2:
The transmission ratio parameter is changed by switching between different winding areas based on input voltage levels. Instead of using a single high-performance component designed for maximum voltage, the system changes the effective transmission ratio parameter dynamically, allowing standard components to operate within their optimal ranges for different voltage conditions.
3Adaptability or versatility
If the storage capacity is increased to handle lower voltages, then adaptability is improved, but device complexity increases due to dynamic capacity adjustment
Solution Approach 1:
The voltage monitoring unit provides continuous feedback on the primary voltage level to the switching mechanism. Based on this feedback, the system automatically adjusts which winding area is active and whether additional capacitors are connected, creating a closed-loop control system that adapts the storage capacity and transmission ratio to match the current voltage conditions without manual intervention.
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 solution allows for a high-efficiency power supply with a large input voltage range, reducing power loss and improving control behavior, while minimizing transformer size and device variants, enabling operation from 20 V to 250 V AC with reduced costs and complexity.
Implementation Method 1
The principle of the flyback converter is that a small amount of energy is stored in the magnetic field of a coil - for example the primary winding of a transformer - and this is then drawn on the secondary side of the transformer
Implementation Method 2
at least one rectifier for rectifying the primary voltage is provided on the primary side
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a device for transmitting electrical power between a primary side (1) and a secondary side (2), having at least one voltage input (3) on the primary side (1), having at least one transformer (4), wherein said transformer (4) has at least one first winding area (5) and one second winding area (6) on said primary side (1), and having at least one voltage monitoring unit (7), wherein said voltage monitoring unit (7) is designed such that the voltage monitoring unit (7) connects the voltage input (3) to the first winding area (5) or the second winding area (6) as a function of a primary voltage, which is applied to the voltage input (3).