Integrated Magnetic DC Converter for Low-Loss Vehicle Power
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Solution Overview
Problem
Existing tension converters in motor vehicles, particularly in electric and hybrid vehicles, face challenges in reducing energy losses, size, and cost while efficiently supplying on-board equipment with a voltage range of 12 to 14V from a high voltage battery system.
Innovation Solution
The use of a magnetic component with a primary winding and two secondary windings, coupled magnetically with the primary but not with each other, allows for energy transfer and storage functions, replacing multiple transformer and inductance components with a single magnetic component. This configuration enables efficient energy transfer and storage while reducing the number of components and size of the converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple separate magnetic components (transformer and inductors) are used for energy transfer and storage, then the converter can perform required functions, but the size and cost of the converter increase
Solution Approach 1:
The patent combines the transformer and inductor functions into a single integrated magnetic component. The magnetic component includes a primary winding for energy transfer (transformer function) and at least one secondary winding for energy storage (inductor function), eliminating the need for separate magnetic components and reducing overall device complexity while maintaining energy efficiency
Solution Approach 2:
The magnetic component is designed to perform multiple functions simultaneously: it acts as both a transformer for energy transfer between circuits and an inductor for energy storage within the same component structure. This multi-functionality reduces the total number of components needed in the voltage converter
2Reliability
If multiple separate magnetic components are used, then the converter can achieve required energy transfer and storage, but the size of the converter increases
Solution Approach 1:
The patent integrates the transformer and inductor into a single magnetic component with shared magnetic core and windings, physically reducing the volume occupied by magnetic components. The primary winding and secondary winding are wound on the same magnetic component, eliminating the space required for separate components while maintaining efficient energy transfer and storage
3Ease of manufacture
If multiple separate magnetic components are used, then the converter can perform energy transfer and storage functions, but the cost of the converter increases
Solution Approach 1:
The patent consolidates multiple ferrite coil functions into a single integrated magnetic component structure, making it easier to manufacture as a unified assembly. The magnetic component with primary and secondary windings can be manufactured as one piece rather than assembling multiple separate ferrite components, improving ease of manufacture and integration
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 solution reduces energy losses, decreases the size and cost of the converter, and meets the requirements of the automotive market by providing a compact and efficient DC/DC voltage converter for hybrid or electric vehicles.
Implementation Method 1
a magnetic component (31) with a primary winding (33) connected to the high voltage circuit (23) and with two secondary windings (35a, 35b) connected to the low voltage circuit (27), said two secondary windings (35a, 35b) being magnetically coupled to the primary winding (33) but not magnetically coupled to each other
Data Source
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AI summary
A DC voltage converter and associated control method. The present invention concerns a DC voltage converter (21) comprising: -at least one magnetic component (31) allowing a transfer of energy between a primary circuit (33) and a secondary circuit (35a, 35b), -a high-voltage circuit (23) linking a high-voltage source (25) to the primary circuit of the at least one magnetic component (31), -a low-voltage circuit (27) linking the secondary circuit of the at least one magnetic component (31) to a low-voltage source (29), in which the primary circuit (33) of the magnetic component (31) comprises a primary winding (33) and the secondary circuit (35a, 35b) of the magnetic component (31) comprises a first (35a) and a second (35b) secondary windings not magnetically coupled to each other, said first (35a) and second (35b) secondary windings being magnetically coupled to the primary winding (33).