Insulated Power Transfer Device With Active Buffer Regulation
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Solution Overview
Problem
Existing power transfer devices in avionics lack high electrical insulation, wide input dynamic range, efficient voltage transformation, and a small footprint, with limitations in efficiency and component stress due to high RMS currents and leakage inductance effects.
Innovation Solution
A hybrid power transfer device combining a switched-mode converter with a magnetic coupler, featuring independent primary and secondary regulation, soft switching at zero voltage, and a voltage step-up circuit with active buffer stages to manage energy storage and reduce component stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a magnetic coupler with full-wave rectifier bridge is used, then efficiency is improved (95%), but input voltage dynamic range is limited (ratio must be <= 2)
Solution Approach 1:
The power transfer device is divided into two independent control systems: a primary side controller managing the H-bridge switches and a secondary side controller managing the rectifier bridge switches. This segmentation allows each controller to independently optimize its side's operation, enabling the primary side to handle wide input voltage variations while the secondary side maintains efficient rectification, thus resolving the contradiction between efficiency and input voltage dynamic range.
Solution Approach 2:
The invention introduces dynamic control where the duration of the simultaneous on-state phase of switches is adjustable according to application requirements and current demands. This dynamic adjustment allows the system to adapt to varying input voltage conditions while maintaining optimal efficiency, effectively expanding the input voltage dynamic range without sacrificing the 95% efficiency achieved by the magnetic coupler configuration.
2Power
If input voltage is low, then transformation ratio can be maintained, but RMS currents increase causing additional losses and requiring severe filtering
Solution Approach 1:
The secondary side controller monitors the output current requirements and provides feedback to adjust the duration of the simultaneous on-state phase of switches. This feedback mechanism allows the system to optimize the energy storage phase duration based on actual load conditions, preventing excessive RMS currents during low input voltage conditions and reducing associated losses in semiconductors and inductive elements while maintaining the required transformation ratio.
3Device complexity
If leakage inductance is used for energy storage, then device complexity is reduced, but component stress increases due to high RMS currents
Solution Approach 1:
The invention changes the operational parameters by introducing independent control of switch timing on both primary and secondary sides. By dynamically adjusting the duration of simultaneous on-state phases based on load requirements and input voltage conditions, the system optimizes current waveforms to reduce RMS values, thereby reducing component stress while maintaining the simple structure that utilizes leakage inductance for energy storage.
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 improved efficiency with reduced losses, a wide input voltage dynamic range, and high transformation ratios without stressing components, while maintaining a compact design and minimizing heat dissipation.
Implementation Method 1
a transformer with a primary winding between two primary terminals, a secondary winding in series with a coupling inductance between two secondary terminals
Implementation Method 2
said coupling inductance comprising at least the leakage inductance of the transformer
Data Source
AI summary
An insulated transfer device with particular topology, comprising on the primary, a switched-mode voltage step-up circuit, with a step-up inductance (LB) and an active buffer stage (DT, MT, CT) supplying a peak voltage greater than the peak voltage supplied by the input voltage source (vE) and two pairs of controlled switches controlling the application of the voltage supplied by the switched-mode voltage step-up circuit, to the terminals (Ep1, Ep2) of the primary winding and to the secondary, a full-wave rectifier with diodes (Ds1, Ds2) and controlled switches (Ms1, Ms2). On the primary, the voltage at the terminals of the capacitor CT of the active buffer stage used to apply a controlled AC voltage between the terminals Ep1 and Ep2 is regulated by controlling the time for which the controlled switches of the pairs are simultaneously in the closed state. On the secondary, VS is regulated by controlling the time for which the secondary switches are simultaneously in the closed state.