Half-Turn Winding Transformer Layout for Flexible Step-Down Ratios
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Solution Overview
Problem
Existing two-stage step-down conversion circuit architectures face limitations in adapting to diverse output voltage demands and suffer from high transformer loss and large size due to restricted step-down ratios and winding configurations.
Innovation Solution
A half-turn winding transformer design with specific winding configurations and magnetic core layout, incorporating multiple windings and channels, allows for flexible step-down ratios and reduced loss, utilizing a magnetic core with two magnetic substrates and side columns, and employing staggered voltage waveforms and interleaved windings to minimize resistance and conduction loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional winding configurations are used in two-stage step-down conversion circuits, then the transformer can achieve basic voltage conversion, but the transformer loss and device size increase
Solution Approach 1:
The transformer winding is divided into multiple independent winding sections (first high-voltage winding, second high-voltage winding, first low-voltage winding combination, second low-voltage winding combination) distributed across different channels. Each winding section can be independently optimized for its specific function, reducing overall transformer loss while maintaining manageable complexity through modular design.
Solution Approach 2:
The patent introduces a multi-channel spatial dimension to the winding configuration, with windings distributed across first and second channels between side columns and middle column. This spatial distribution reduces winding loss by minimizing interleaving requirements while maintaining voltage conversion functionality, effectively solving the contradiction between loss reduction and complexity management.
2Adaptability or versatility
If fixed step-down ratios are used in the transformer, then the winding configuration is simple, but the adaptability to diverse output voltage demands is limited
Solution Approach 1:
The transformer is designed with multiple high-voltage windings and multiple low-voltage winding combinations that can be connected in different configurations. This universal design allows the same transformer structure to achieve multiple step-down ratios (4:1, 8:1, 12:1 and others) by reconfiguring the winding connections, providing diverse output voltage adaptability without requiring separate transformers for each ratio.
Solution Approach 2:
The winding configuration enables dynamic adaptation to different output voltage requirements through selectable connection modes. The transformer can switch between different operating states by reconfiguring which winding sections are active and how they are connected, allowing the step-down ratio to be adjusted dynamically based on application requirements while maintaining a single physical device structure.
3Volume of moving object
If the transformer is designed for high power density, then the size is reduced, but the transformer loss may increase due to constrained winding space
Solution Approach 1:
By segmenting the windings into multiple sections distributed across different channels and columns, the patent reduces the winding length required in any single location. This segmentation allows for more efficient use of the limited winding space in a compact transformer, reducing resistive losses while maintaining small overall size through optimized spatial distribution of winding elements.
Solution Approach 2:
The middle column acts as an intermediary structure that facilitates efficient magnetic coupling between windings in a compact footprint. By positioning windings around the middle column and distributing them across channels, the design achieves effective magnetic linkage with reduced leakage inductance and lower losses, enabling high power density without sacrificing efficiency.
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 design achieves wider output voltage adaptability, reduced transformer loss, and smaller size, enhancing the efficiency and power density of power conversion devices.
Implementation Method 1
Half-turn winding transformer, comprising a magnetic core and windings... the intermediate bus conversion (IBC) device in the two-stage step-down conversion circuit architecture is used for realizing voltage conversion between an input bus and an output bus
Data Source
AI summary
The application discloses a half-turn winding transformer, a circuit topology and a power device The half-turn winding transformer comprises a magnetic core, two high-voltage windings and four low-voltage windings; the magnetic core comprises two magnetic substrates and at least three magnetic columns, and the at least three magnetic columns are arranged in a row. According to the half-turn winding transformer, the step-down ratio between various input voltages and output voltages of the intermediate bus conversion device can be realized, and the application of different output voltage requirements is met; and on the other hand, by designing the winding mode and the device layout of the transformer, the loss of the transformer is reduced, and the size of the transformer is reduced.