Integrated Magnetic Apparatus for DC-DC Converter Size Reduction
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Solution Overview
Problem
Conventional DC-DC converters for electric vehicle chargers are bulky and costly due to the need for multiple converters and complex control systems, which increases the size and cost proportionally with battery capacity, and they face heat generation issues.
Innovation Solution
A single DC-DC converter with an integrated magnetic apparatus that combines a transformer and inductor into a single structure, utilizing a cooling bar to manage heat and reduce the number of components, thereby minimizing size and cost, and employing a single microcomputer to simplify control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple converters are used to increase battery charger capacity, then charging capacity is improved, but device size and cost increase proportionally
Solution Approach 1:
The patent combines multiple converter functions into a single integrated magnetic apparatus that houses both the PFC converter and DC-DC converter. This integration allows the system to achieve high charging capacity (11kW level) while reducing the overall physical size by eliminating separate converter housings and control units.
Solution Approach 2:
The integrated magnetic apparatus performs multiple functions simultaneously - it serves as both the PFC converter and DC-DC converter, and contains both transformer and inductor functions within a single structure. This multi-functionality enables one device to replace what would traditionally require multiple separate converters.
2Power
If multiple converters are used to increase battery charger capacity, then charging capacity is improved, but device cost increases due to more microcomputers and complex circuits
Solution Approach 1:
The patent integrates the control systems of both PFC and DC-DC converters into a single microcomputer unit. This unified control approach reduces the total number of microcomputers from multiple separate units to one, thereby lowering cost and simplifying the control circuitry while maintaining the ability to handle high charging capacity.
3Productivity
If converter capacity is increased to reduce charging time, then charging speed is improved, but heat generation increases
Solution Approach 1:
The patent converts the harmful heat generated by high-power conversion into a manageable thermal issue by integrating heat dissipation structures directly into the magnetic apparatus. The housing design incorporates thermal management features that efficiently channel and dissipate heat, transforming the heat problem into a controlled thermal management solution.
4Power
If multiple converters are used to increase battery charger capacity, then charging capacity is improved, but the number of control microcomputers increases
Solution Approach 1:
A single microcomputer in the integrated magnetic apparatus is designed to perform the control functions of both PFC and DC-DC converters. This multi-functional control unit replaces what would traditionally require multiple separate microcomputers, reducing component count while maintaining full control capability for high-capacity charging operations.
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 integrated magnetic structure reduces the overall size, weight, and cost of the DC-DC converter while effectively managing heat, thus enhancing the efficiency and reliability of electric vehicle charging systems.
Implementation Method 1
a cooling bar provided on a central portion of the housing part, passing through a central portion of the bottom surface, and provided in parallel with at least one pillar
Implementation Method 2
first and second transforming parts transforming an output of the switching part
Data Source
AI summary
A single direct current (DC)-DC converter may include a switching part switching an input DC voltage; first and second transforming parts transforming an output of the switching part; a rectifying part rectifying outputs of each of the first and second transforming parts; and an output part filtering and outputting an output of the rectifying part.