Flying Capacitor Converter Layout With Auxiliary Winding Support
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Solution Overview
Problem
The increasing power requirements of intelligent data processing chips, such as GPUs and NPUs, lead to higher server power consumption and lower output voltage conversion efficiency, necessitating a more efficient power conversion device.
Innovation Solution
A power conversion device is designed with an auxiliary winding and switch, and optimized layout of transformer and inductor components, to provide sufficient energy to the output end even when the input voltage is lower than four times the output voltage, while reducing parasitic parameters and improving conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the input voltage is lower than four times the output voltage, then the conventional two-stage voltage-reduction circuit cannot provide sufficient energy to the output end, but adding an auxiliary winding and auxiliary switch increases device complexity
Solution Approach 1:
The auxiliary winding is integrated into the existing transformer structure, allowing the transformer to serve both its original voltage reduction function and the additional function of providing sufficient energy to the output end when input voltage is low. The auxiliary switch works in coordination with existing switches to enable the circuit to adapt to different input voltage conditions without requiring completely separate circuit paths.
2Loss of energy
If the layout of transformer and inductor is optimized to reduce parasitic parameters, then conversion efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The transformer and inductor are positioned in close proximity and their winding layouts are coordinated to minimize the distance between connected components. This merging approach reduces the parasitic inductance and resistance in the power transmission path without requiring completely separate optimized layouts for each component, thus balancing performance improvement with manufacturability.
3Loss of energy
If the gain ratio of output voltage to input voltage is reduced to achieve high conversion efficiency, then the intermediate bus voltage must be lowered from 12V to 6.75V or 3.3V, but this limits the adaptability to different input voltage conditions
Solution Approach 1:
The circuit incorporates an auxiliary switch that can be dynamically controlled based on the input voltage level. When the input voltage is sufficient, the conventional two-stage reduction path is used for high efficiency. When the input voltage drops below four times the output voltage, the auxiliary switch activates to provide the additional energy path, allowing the circuit to adapt its configuration based on operating 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 ensures efficient energy transfer and reduced power loss by optimizing the layout of key components and using an auxiliary circuit to support energy delivery across a wide range of input voltages.
Implementation Method 1
a transformer... a winding of the transformer penetrates through the transformer winding area
Implementation Method 2
an inductor... by improving the layout of the transformer, the inductor and other power devices
Data Source
AI summary
A power conversion device is provided. The power conversion device is applied to a circuit topology and layout of the six-switch flying capacitor voltage reduction type conversion circuit which is applied to the intermediate bus converter. The layout of the transformer and the inductor is provided, so that the parasitic resistance of the winding in the magnetic core assembly is minimum. An auxiliary switch and an auxiliary winding are additionally arranged on the six-switch flying capacitor voltage reduction type conversion circuit, and the auxiliary switch and the auxiliary winding are used for providing enough energy for the output end when the input voltage is lower than four times of the output voltage. A switch layout is provided to reduce parasitic parameters and power losses of a transformer winding AC loop, and parasitic parameters and power losses on the switch bridge arm path.