Full Bridge DC-DC Converter With Current Doubler
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Solution Overview
Problem
Conventional full bridge DC-DC converters experience transformer saturation due to contact resistance deviations when the inductor and transformer are coupled by a screw, leading to increased heat, loss, and noise generation.
Innovation Solution
The coupling sequence of the output inductor and diode to the transformer's secondary side is altered to minimize contact resistor effects, with symmetrical contact resistors and screws used to maintain zero DC offset, reducing the risk of transformer saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inductor and transformer are coupled by a screw, then the manufacturing process is simplified and ease of manufacture is improved, but contact resistance deviation occurs leading to transformer saturation and increased heat loss
Solution Approach 1:
The patent applies preliminary action by pre-configuring symmetrical contact resistors in the circuit design before assembly. This allows the system to compensate for contact resistance deviations that will occur during screw coupling, preventing transformer saturation and reducing heat loss while maintaining ease of manufacture.
Solution Approach 2:
The patent changes the circuit parameters by introducing symmetrical contact resistors with specific resistance values. This parameter modification allows the circuit to tolerate contact resistance variations from screw coupling without causing transformer saturation, thus reducing energy loss while keeping the manufacturing process simple.
2Ease of manufacture
If the inductor and transformer are coupled by a screw, then manufacturing simplicity is improved, but contact resistance deviation causes current unbalance and transformer saturation
Solution Approach 1:
The patent modifies circuit parameters by adding symmetrical contact resistors that compensate for contact resistance variations. This allows the system to maintain proper current balance and prevent transformer saturation even when screw coupling causes contact resistance deviations, thus preserving manufacturing simplicity without sacrificing electrical performance.
Solution Approach 2:
The symmetrical contact resistor configuration provides a form of passive feedback compensation. The circuit design anticipates contact resistance variations and uses the symmetrical resistor arrangement to automatically compensate for these deviations, maintaining current balance without requiring precision screw coupling.
3Ease of operation
If conventional coupling sequence is used, then assembly is simplified, but DC offset current is generated causing transformer saturation and increased noise
Solution Approach 1:
The patent applies preliminary action by designing the circuit with symmetrical contact resistors configured in advance. This pre-configuration ensures that even when conventional assembly sequences are used, the circuit maintains current balance and prevents DC offset generation, thereby eliminating transformer saturation and noise without complicating the assembly process.
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 reduces heat and loss in switch elements and noise generation by maintaining zero DC offset in the transformer, preventing saturation and allowing for a screw coupling process that replaces welding, thereby improving efficiency and manufacturing simplicity.
Implementation Method 1
a transformer that reduces a high AC voltage supplied to a primary side (301) thereof and then outputs the AC voltage to a secondary side (302)
Implementation Method 2
a switching circuit that converts a transmitted high DC voltage into a high AC voltage and then outputs the high AC voltage to the primary side of the transformer
Data Source
AI summary
A full bridge DC-DC converter to which a current doubler is applicable is provided and includes a transformer and a switching circuit that converts a high direct current voltage into a high alternating current voltage and then outputs the high alternating current voltage to the primary side of the transformer. In addition, an output circuit receives and processes the output of the secondary side of the transformer and supplies the processed output to an electric load. The output circuit includes a first inductor, a first contact resistor, a second inductor, a second contact resistor, a first diode, a third contact resister, a second diode, and a fourth contact resister.