Integrated Synchronous Rectifier in Heavy-Current Transformer
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Solution Overview
Problem
Resistance welding devices experience high losses due to heavy-current transformers and power lines, leading to inefficient energy use and significant heat dissipation, resulting in poor efficiency and high operational expenses in production lines.
Innovation Solution
Integration of a synchronous rectifier and its actuation circuit within a heavy-current transformer, eliminating the need for control lines and minimizing line lengths, with a compact design that includes multi-point contacting and direct connections between components to reduce ohmic and contact losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If separate design of heavy-current transformer and rectifier is used, then device complexity is reduced and ease of manufacture is improved, but line lengths increase causing higher power losses and lower efficiency
Solution Approach 1:
The patent combines the heavy-current transformer and synchronous rectifier into a single integrated unit. The rectifier circuit is directly coupled to the transformer windings, eliminating separate power lines and control lines between independent components. This merging reduces ohmic losses and contact losses while maintaining manageable device complexity through modular integration.
2Loss of energy
If active rectifiers with control elements are used, then rectification efficiency is improved compared to diode rectifiers, but losses remain relatively high and efficiency is still poor
Solution Approach 1:
The synchronous rectifier uses the heavy current itself to provide the control signals for switching the transistors. The current flowing through the windings directly actuates the rectifier elements, eliminating the need for separate control lines and external control circuits. This self-service mechanism reduces additional power losses while maintaining high rectification efficiency.
Solution Approach 2:
The patent replaces traditional diode rectification with synchronous rectification using controlled transistors. This substitution allows for more efficient current conversion by actively controlling the switching elements, reducing power losses while the integrated design and self-service actuation maintain system simplicity.
3Power
If heavy currents are used in resistance welding devices, then welding performance is improved, but power losses increase significantly reducing efficiency to only some 10%
Solution Approach 1:
By integrating the transformer and rectifier into a single unit with direct coupling, the patent eliminates long power lines and multiple contact points. This merging reduces ohmic losses and contact losses that would otherwise be significant at heavy currents of 15-40 kA, thereby improving overall efficiency while maintaining the required welding power.
4Productivity
If integrated design of synchronous rectifier and transformer is implemented, then power dissipation is reduced and efficiency is improved, but device complexity increases
Solution Approach 1:
The integrated unit is designed with clear functional segmentation: primary windings, secondary windings with center tapping, synchronous rectifier circuit, and actuation circuit. This segmentation allows for systematic manufacturing and assembly while achieving the efficiency benefits of integration. The modular structure manages device complexity through organized functional zones.
5Loss of energy
If line lengths are minimized through integration, then ohmic losses and contact losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The integration merges the transformer and rectifier into a single manufacturable unit with minimized internal connections. The direct coupling eliminates the need for separate power lines and control lines, reducing ohmic and contact losses. The unified design simplifies assembly procedures while maintaining ease of manufacture through standardized integration processes.
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 configuration significantly reduces power dissipation, increases efficiency, and allows for a more compact and lightweight power source, capable of operating at higher switching frequencies, thereby minimizing line losses and enhancing user convenience.
Implementation Method 1
a heavy-current transformer with at least one primary winding and at least one secondary winding with center tapping
Implementation Method 2
a synchronous rectifier connected with the at least one secondary winding of the heavy-current transformer and comprising circuit elements
Implementation Method 3
a method for cooling a power source for providing a direct current
Implementation Method 4
measures must be taken to dissipate the heat
Data Source
AI summary
The invention relates to a power source (10) for providing a direct current, comprising a heavy-current transformer (12) with at least one primary winding (13) and at least one secondary winding (14) with center tapping, a synchronous rectifier (16) connected with the at least one secondary winding (14) of the heavy-current transformer (12) and comprising circuit elements (24), and a circuit (17) for actuating the circuit elements (24) of the synchronous rectifier (16), and a supply circuit (48) for supplying the synchronous rectifier (16) and the actuation circuit (17), and to a method for cooling such a power source (10). For reduction of losses and improvement of efficiency, the synchronous rectifier (16) and the actuation circuit (17) and the supply circuit (48) thereof are integrated in the heavy-current transformer (12).