Inductively Balanced Power Supply Circuit with Magnetic Shunts
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Solution Overview
Problem
Current double current-doubler power supply circuits face challenges in maintaining a power-dense architecture while minimizing ripple voltage and maximizing output current, as inductor proximity leads to magnetic coupling issues that increase ripple current and reduce power density.
Innovation Solution
An inductively balanced power supply circuit is designed with first and second inductor assemblies positioned close together on a printed circuit board, utilizing magnetic shunts to balance mutual inductance between the inductors, allowing for magnetic coupling while minimizing ripple voltage and maintaining high output current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If inductors are positioned in close proximity to maintain power-dense architecture, then power density is improved, but magnetic coupling increases ripple current
Solution Approach 1:
A magnetic shunt is introduced as an intermediary element between the inductors to manage and balance the magnetic coupling. The shunt provides a controlled path for magnetic flux, acting as a mediator that allows the inductors to be positioned close together while preventing harmful magnetic interference that would increase ripple current.
Solution Approach 2:
The magnetic shunt alters the magnetic circuit parameters by providing a low-reluctance path for flux. This changes the distribution and magnitude of magnetic coupling between inductors, enabling close positioning without the adverse ripple current effects that would normally occur at such proximity.
2Object-generated harmful factors
If inductors are physically separated to prevent magnetic coupling, then ripple current is reduced, but power density decreases
Solution Approach 1:
The magnetic shunt serves as a mediator that eliminates the need for physical separation. By introducing this intermediate magnetic path, the system achieves the ripple current reduction normally requiring large spacing while maintaining compact inductor positioning for high power density.
Solution Approach 2:
Instead of solving the magnetic coupling problem in the spatial dimension (by increasing distance), the solution moves to the magnetic circuit dimension by introducing a shunt path. This dimensional shift allows close physical positioning while controlling magnetic interactions through the shunt's magnetic path.
3Stability of the object's composition
If mutual inductance is balanced using magnetic shunts, then output voltage stability is improved, but device complexity increases
Solution Approach 1:
Magnetic shunts are introduced as intermediary elements to balance mutual inductance between inductors. These shunts provide controlled magnetic paths that stabilize the magnetic coupling, thereby improving output voltage stability without requiring complex electronic control circuits.
Solution Approach 2:
The solution replaces potential complex electronic control mechanisms with passive magnetic shunt elements. By using magnetic path management instead of active electronic balancing, the system achieves voltage stability with simpler, more reliable passive components.
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 achieves a stable, low-ripple output voltage with high output current, maintaining a power-dense architecture by balancing mutual inductance through the strategic placement of magnetic shunts, resulting in a 48:1 power conversion ratio with an output current of approximately 230 amps and a ripple voltage of 20 millivolts.
Implementation Method 1
the inductors of each current-doubler are disposed in close proximity (e.g., to accommodate a power dense converter architecture) and tend to magnetically couple during operation
Implementation Method 2
a first magnetic shunt coupled to the outer edge of the first inductor assembly, and a second magnetic shunt coupled to the outer edge of the second inductor assembly
Data Source
AI summary
A power supply circuit includes a printed circuit board (PCB), and a transformer coupled to the PCB. The power supply circuit also includes a first inductor assembly coupled to the PCB and electrically connected to the transformer, and a second inductor assembly coupled to the PCB and electrically connected to the transformer. The first inductor assembly has an inner edge and an opposite outer edge, and the second inductor assembly has an inner edge and an opposite outer edge. The inner edge of the second inductor assembly is spaced apart from the inner edge of the first inductor assembly by a gap. The power supply circuit also includes a first magnetic shunt coupled to the outer edge of the first inductor assembly, and a second magnetic shunt coupled to the outer edge of the second inductor assembly.