Integrated Reactor Topology for Low-Ripple Power Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power conversion devices face challenges in downsizing reactors and reducing current ripple, particularly in bridge-less power factor correction configurations, where current dividing and magnetic flux cancellation are not effectively addressed, leading to inefficiencies and increased losses.
Innovation Solution
The power conversion device integrates multiple reactors onto a single core, allowing for interleave driving and in-phase driving control to uniform heat dissipation and reduce size, while utilizing a magnetic resistor network to manage magnetic flux and inductance, thereby minimizing current ripple and losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple reactors are integrated onto a single core, then device size is reduced, but current ripple increases
Solution Approach 1:
The patent divides the single core into multiple magnetic circuits, each handling a specific phase or function. The core is segmented into separate leg structures with independent magnetic paths, allowing each segment to manage its own current ripple characteristics while contributing to the overall integrated structure.
Solution Approach 2:
The patent employs asymmetric winding configurations where windings are arranged with different numbers of turns and orientations on different legs of the core. This asymmetric arrangement creates opposing magnetic fluxes that cancel each other's ripple effects, reducing overall current ripple while maintaining compact integration.
2Reliability
If DC magnetic fluxes are made to cancel out each other, then magnetic flux saturation is prevented, but DC inductance can only be formed by leakage magnetic flux
Solution Approach 1:
The patent introduces a third dimensional aspect by adding a vertical leg structure to the magnetic core, creating a three-dimensional magnetic circuit. This allows DC flux cancellation in the horizontal plane while maintaining independent DC inductance paths through the vertical dimension, enabling both saturation prevention and efficient inductance formation.
Solution Approach 2:
The patent uses the magnetic core structure itself as an intermediary element that facilitates both flux cancellation and inductance formation. The core's geometric design and winding arrangement act as a mediator that separates the conflicting requirements of flux cancellation and inductance generation into distinct magnetic paths.
3Loss of energy
If interleave driving is used, then loss and current ripple are reduced, but heat distribution becomes uneven
Solution Approach 1:
The patent merges multiple magnetic circuits into a single integrated core structure where heat generation from different phases is physically combined. This integration allows heat to distribute more uniformly across the entire core mass, preventing localized hot spots while maintaining the loss-reduction benefits of interleave driving.
Solution Approach 2:
The patent applies different winding configurations and magnetic path designs to different local regions of the core, optimizing each region's characteristics. By tailoring the magnetic properties locally, the patent achieves uniform heat distribution across different zones while maintaining overall system efficiency.
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 approach achieves reduced heat dissipation and size reduction by controlling interleave and in-phase driving modes, resulting in lower current ripple and increased efficiency, and allows for a more compact filter design in power supply applications.
Implementation Method 1
the first winding 2a and the second winding 2b are coupled to each other by magnetic coupling
Implementation Method 2
AC magnetic fluxes are canceled out by each other
Implementation Method 3
heat in the DC winding 2c and the coupled windings 2a, 2b can be uniformed
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A power conversion device including: a reactor (2) formed such that a DC winding (2c) and a plurality of coupled windings (2a, 2b) are wound around one magnetic body, one end of the DC winding (2c) is connected to a voltage source, one end of each of the plurality of coupled windings (2a, 2b) is connected to another end of the DC winding (2c), another end of each of the plurality of coupled windings (2a, 2b) is connected to each intermediate connection point between a plurality of upper and lower arms composed of switching elements (Sa, Sb, Sc, Sd), and magnetic fluxes generated by currents flowing through the DC winding (2c) and the coupled windings (2a, 2b) merge with each other in the same direction; and a control device (10) for controlling the switching elements (Sa, Sb, Sc, Sd), wherein the upper arms or the lower arms are controlled by in-phase driving or interleave driving on the basis of the duty of switching operation.