Integrated Magnetic Assembly for Compact EV Power Modules
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Solution Overview
Problem
Conventional on-board chargers for electric vehicles suffer from high spatial volume, heavy weightiness, and high cost due to the separate circuitry topologies of unidirectional and bidirectional power flow modules, requiring multiple magnetic elements.
Innovation Solution
An integrated magnetic assembly that combines an LLC resonant circuit with an auxiliary power module, integrating the transformer and secondary inductor into a single magnetic core, reducing the number of magnetic elements to two, and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate circuitry topologies for unidirectional power flow on-board charger and auxiliary power module are used, then the functions are combined together, but the spatial volume, weightiness, and cost increase due to multiple magnetic elements
Solution Approach 1:
The patent merges the transformer and secondary inductor into a single integrated magnetic assembly, reducing the number of separate magnetic elements from four or five to just two. This consolidation maintains the combined functions of unidirectional power flow on-board charger and auxiliary power module while significantly reducing spatial volume and weightiness.
Solution Approach 2:
The integrated magnetic assembly serves multiple functions simultaneously - acting as both the transformer and secondary inductor for the hybrid power module. This multi-functionality allows the system to achieve both unidirectional and bidirectional power flow capabilities with fewer components, thereby reducing overall spatial volume while maintaining versatility.
2Adaptability or versatility
If separate circuitry topologies for unidirectional power flow on-board charger and auxiliary power module are used, then the functions are combined together, but the weightiness increases due to multiple magnetic elements
Solution Approach 1:
The patent merges the transformer and secondary inductor into a single integrated magnetic assembly, reducing the number of separate magnetic elements from four or five to just two. This consolidation maintains the combined functions of unidirectional power flow on-board charger and auxiliary power module while significantly reducing spatial volume and weightiness.
3Adaptability or versatility
If separate circuitry topologies for unidirectional power flow on-board charger and auxiliary power module are used, then the functions are combined together, but the cost increases due to multiple magnetic elements
Solution Approach 1:
The patent merges the transformer and secondary inductor into a single integrated magnetic assembly, reducing the number of separate magnetic elements from four or five to just two. This consolidation maintains the combined functions of unidirectional power flow on-board charger and auxiliary power module while significantly reducing spatial volume and weightiness.
4Reliability
If multiple magnetic elements are used in hybrid power module, then the circuitry topologies are complete, but the spatial volume and weightiness increase
Solution Approach 1:
The patent merges the transformer and secondary inductor into a single integrated magnetic assembly, reducing the number of separate magnetic elements from four or five to just two. This consolidation maintains the combined functions of unidirectional power flow on-board charger and auxiliary power module while significantly reducing spatial volume and weightiness.
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 assembly achieves a smaller spatial volume, lighter weight, and lower cost while maintaining functionality, with improved heat dissipation.
Implementation Method 1
The magnetic assembly includes at least one magnetic core and at least one winding assembly. Each magnetic core includes a first magnetic leg and a second magnetic leg. The first winding and the second winding are wound around the first magnetic leg. The third winding is wound around the second magnetic leg and the first magnetic leg.
Implementation Method 2
A channel is formed between the first magnetic leg and the second side of the second magnetic leg. Each winding assembly includes a first winding, a second winding and a third winding. The first winding and the second winding are wound around the first magnetic leg. A part of the first winding and a part of the second winding are accommodated within the channel.
Data Source
AI summary
The present disclose provides a magnetic assembly and a power module. In one aspect, the magnetic assembly includes a magnetic core having a first magnetic leg and a second magnetic leg spatially separated from the first magnetic leg to define a spatial channel therebetween, and a winding assembly comprising a first winding, a second winding, and a third winding. The first and second windings are wound around the first magnetic leg with at least a part of the first and second windings being accommodated within the spatial channel. The third winding is wound around the first and second magnetic legs. The first winding is disposed between the first magnetic leg and the second winding. The second winding is disposed between the first winding and the third winding.