Integrated Transformer Rectifier Module for Vehicle DC-DC Converters
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Solution Overview
Problem
Conventional electric power converters for vehicles, such as DC/DC step-down converters, are complex and costly due to numerous components and a lack of standardization, making them difficult to adapt to various car sizes and interface positions, leading to increased costs and assembly complications.
Innovation Solution
The electric power converter integrates a transformer and rectifier elements into a single module with a center tap configuration, allowing for standardized main components, reduced size, and lower costs by using a connecting object to link the pullout portion of the center tap and smoothing coil, enabling flexibility in component arrangement and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (transformer, rectifier elements, smoothing reactor) are used separately in conventional DC/DC converters, then each component can be optimized individually, but the overall device size, assembly complexity, and cost increase
Solution Approach 1:
The patent combines the transformer and rectifier elements into a single integrated module where the rectifier elements are mounted directly on the transformer housing or core structure. This merging eliminates the need for separate mounting brackets, wiring harnesses, and assembly steps, thereby reducing device complexity and assembly complexity while maintaining individual component optimization
Solution Approach 2:
The transformer housing or core structure serves multiple functions: it provides magnetic shielding, structural support, and a mounting platform for the rectifier elements. This multi-functionality reduces the total number of components needed and simplifies the overall device structure without compromising component performance
2Ease of manufacture
If conventional fixed-arrangement components are used, then manufacturing is straightforward, but adaptability to various car sizes and interface positions is limited
Solution Approach 1:
The patent employs adjustable mounting structures that allow the integrated module to be positioned at different locations and orientations within the vehicle. The mounting brackets and connecting terminals are designed with adjustment capabilities, enabling the same standardized module to adapt to various car sizes and interface positions while maintaining manufacturing simplicity
Solution Approach 2:
The power converter system is divided into a standardized integrated module that can be independently manufactured and then installed in different configurations. This segmentation allows the core component to be produced once with high precision while the mounting and connection elements provide the necessary adaptability to different vehicle platforms
3Adaptability or versatility
If transformer internal configuration is changed to adapt to different requirements, then adaptability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The transformer is designed with a universal internal configuration that can serve multiple applications. The winding arrangements and core structure are standardized to handle various power conversion requirements through external circuit configurations rather than internal transformer modifications, thereby maintaining manufacturing simplicity while achieving adaptability
Solution Approach 2:
Instead of changing the physical internal configuration of the transformer, the patent achieves adaptability by adjusting electrical parameters such as winding connections (series/parallel), tap positions, and external circuit topologies. This allows a single transformer design to serve multiple functions without increasing manufacturing complexity
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 results in a downsized, cost-effective electric power converter that can be easily adapted to different vehicle requirements, simplifying assembly and reducing component complexity while maintaining efficient power conversion.
Implementation Method 1
a transformer which is connected to an output side of the inverter circuit
Implementation Method 2
rectifier elements which rectify a voltage which is induced at the secondary side winding of the transformer
Data Source
AI summary
Obtain an electric power converter by which a downsizing and a low cost can be realized in such a way that main components are standardized. A transformer and rectifier elements of a rectifier circuit are configured by using a single module, and a center tap is configured by laminating one pullout portion of a first secondary winding and one pullout portion of a second secondary winding, and a central connecting component is connected to a center tap and a terminal of a smoothing coil which composes a smoothing reactor.