Integrated Magnetic Structure for Power Conditioner Mass Reduction
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Solution Overview
Problem
The existing Electronic Power Conditioners (EPCs) for Solid State Power Amplifiers (SSPAs) in satellite communication face challenges in achieving high efficiency and minimizing mass, which are critical for reducing the mass penalty in space programs and ensuring reliable power transmission.
Innovation Solution
A high-efficiency main stage converter based on a Full-Bridge input switch with an integrated magnetic structure and Hy-bridge rectification using synchronous rectifiers, which includes a clamped Full-Bridge circuit and a Fly-back converter for auxiliary power supply, optimized for efficiency and mass reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional separate magnetic components are used in EPC, then device complexity is reduced, but mass and efficiency are worsened
Solution Approach 1:
The patent combines the main transformer and output filter inductors into a single integrated magnetic structure. The transformer primary and secondary windings are wound on the same magnetic core, eliminating the need for separate inductor components. This integration reduces the total number of magnetic components while improving efficiency by reducing parasitic inductance and optimizing magnetic flux utilization.
2Weight of stationary object
If multiple separate magnetic components are used, then manufacturing is simplified, but mass penalty increases
Solution Approach 1:
The integrated magnetic structure consolidates multiple magnetic components (transformer and filter inductors) into a single assembled unit with one magnetic core and shared windings. This reduces the total mass of magnetic materials required and eliminates the mass of additional mounting hardware, while the integrated design simplifies the assembly process by reducing the number of separate components to be mounted and connected.
3Loss of energy
If conventional rectification is used, then device complexity is low, but efficiency is limited
Solution Approach 1:
The patent replaces conventional passive diode rectification with active synchronous rectification using MOSFETs. The MOSFETs are controlled to act as ideal switches during rectification, replacing the mechanical/semiconductor diode switching mechanism. This substitution reduces conduction losses significantly while the control circuitry adds minimal complexity compared to the overall converter system.
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 achieves an efficiency of over 93% with a significant reduction in mass, improved EMC performance, and simplified design, addressing the key parameters of efficiency and mass while ensuring reliable power transmission and reduced development time.
Implementation Method 1
a main transformer and at least one output choke having an integrated magnetic structure coupled to the output of the bridge circuit
Implementation Method 2
at least one rectifier for rectification of voltage received from the bridge circuit
Data Source
AI summary
A power supply including a main stage converter having a bridge circuit having input switches for receiving input voltage and providing an output, a main transformer and at least one output choke having an integrated magnetic structure coupled to the output of the bridge circuit and at least one rectifier for rectification of voltage received from the bridge circuit and providing a first output voltage.