Integrated Magnetic Component for Vehicle Power Converter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle power supplies face challenges due to harsh environmental conditions, with power isolation transformers and output filter inductors being large, heavy, and affecting power conversion efficiency and mechanical properties, necessitating a reduction in the number and size of magnetic components while enhancing reliability.
Innovation Solution
An integrated magnetic component is developed, combining a secondary center-tapped transformer and an output filter inductor with a magnetic core and windings, where the primary and secondary windings are wound on one column, and the inductor winding is on another, reducing component connections and weight, and forming an integrated winding to minimize air gap fringing field losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power isolation transformer and output filter inductor are used, then electrical isolation and filtering functions are achieved, but the size and weight of magnetic components increase
Solution Approach 1:
The patent combines the power isolation transformer and output filter inductor into a single integrated magnetic component with a shared magnetic core. The transformer windings (primary and secondary) and inductor windings are wound on different columns of the same magnetic core, merging two previously separate magnetic components into one, thereby reducing overall weight while maintaining both electrical isolation and filtering functions.
2Reliability
If separate power isolation transformer and output filter inductor are used, then electrical isolation and filtering functions are achieved, but the overall volume of magnetic components increases
Solution Approach 1:
The patent integrates the transformer and inductor functions into a single magnetic component structure. The magnetic core includes multiple columns where transformer windings and inductor windings are separately wound, combining two separate magnetic volumes into one shared volume, thereby reducing the overall space occupied while maintaining both electrical isolation and filtering capabilities.
3Reliability
If multiple separate magnetic components are used, then functional requirements are met, but the number of component connections increases
Solution Approach 1:
The patent merges the transformer and inductor into a single integrated component, eliminating the need for external connections between separate components. The transformer secondary winding and inductor winding are internally connected through the magnetic core structure, reducing the number of external component connections and simplifying the overall circuit assembly.
4Reliability
If multiple separate magnetic components are used, then functional requirements are met, but power conversion efficiency decreases due to connection losses
Solution Approach 1:
The patent integrates the transformer and inductor into a single magnetic component, eliminating external connection points between separate components. This internal integration removes the connection losses that would occur at external terminals and inter-component connections, thereby improving power conversion efficiency while maintaining the required electrical isolation and filtering functions.
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 integration reduces the overall size and weight of magnetic components, enhances mechanical properties, and improves power conversion efficiency, resulting in a more robust and reliable structure suitable for harsh vehicle environments.
Implementation Method 1
The magnetic core includes at least four magnetic columns, and the windings are wound on the magnetic core. The windings include a primary winding, a first secondary winding, a second secondary winding, and an inductor winding.
Implementation Method 2
The inductor winding is wound on another magnetic column of the magnetic columns, wherein an end of the inductor winding is coupled to a connection where the first secondary winding and the second secondary winding couple to each other.
Data Source
AI summary
An integrated magnetic component includes a magnetic core and a plurality of windings. The magnetic core includes at least four magnetic columns. The windings include a primary winding, a first secondary winding, a second secondary winding, and an inductor winding. The primary winding, the first secondary winding and the second secondary winding are wound on one of the magnetic columns. The inductor winding is wound on another magnetic column, and the inductor winding is coupled to the connection where the first secondary winding and the second secondary winding couple to each other. By integrating a transformer and a filter inductor into the integrated magnetic component, the number of the magnetic components, the overall volume, and the weight may be reduced while the mechanical properties may be promoted and the loss of the component connections may be reduced.