Interleaved Multiphase Converter With Coupled Inductor and Active Clamp
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Solution Overview
Problem
Existing DC-DC converters for battery energy storage systems, particularly in applications like electric vehicles and renewable energy, face challenges in efficiently boosting low input voltages to higher levels required for battery, fuel cell, and solar applications, often resulting in complex designs and reduced flexibility.
Innovation Solution
A multiphase converter topology incorporating a coupled inductor and active clamp circuit, which includes a main switch circuit, active clamp circuit, and voltage multiplier cell, allowing for high-gain voltage transformation with a wide input voltage range, suitable for both low and high voltage inputs, and enabling flexible operation modes to achieve high efficiency and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing DC-DC converter designs are used to boost low input voltages, then voltage transformation is achieved, but the design becomes complex and flexibility is reduced
Solution Approach 1:
The converter is designed with a universal topology that can handle both low voltage (e.g., 48V) and high voltage (e.g., 400V) inputs using the same circuit architecture. The coupled inductor and active clamp circuit work together to provide voltage boosting functionality across different input ranges, eliminating the need for separate converter designs for different voltage levels and thereby improving flexibility while maintaining manageable complexity.
Solution Approach 2:
The converter employs dynamic switching control of the main switches and active clamp switches to adapt its operation to different input voltage conditions. The duty cycle and switching frequencies are dynamically adjusted based on the input voltage level, allowing the same circuit to optimally boost both low and high voltages without requiring fixed, complex design modifications for each voltage range.
2Adaptability or versatility
If conventional converter topologies are used, then voltage boosting is achieved, but the design lacks adaptability for wide input voltage ranges
Solution Approach 1:
The active clamp circuit serves as an intermediary mechanism that mediates between the coupled inductor and the output, enabling the converter to handle wide input voltage ranges. The active clamp circuit captures and recycles the leakage energy from the coupled inductor, providing a controlled pathway for energy transfer that adapts to different input voltages without requiring complex topology changes.
Solution Approach 2:
The patent merges the voltage boosting function and the leakage energy recovery function into a single integrated topology using the coupled inductor and active clamp circuit. This combination allows the converter to achieve wide input voltage range adaptability through one unified design rather than requiring separate circuits for voltage boosting and energy recovery, thereby managing complexity while expanding adaptability.
3Productivity
If high-gain voltage transformation is implemented, then efficiency is improved, but the converter requires complex circuit configurations
Solution Approach 1:
The active clamp circuit converts the harmful leakage energy from the coupled inductor into a beneficial resource by capturing and recycling it through the clamp switches and capacitor. This approach improves voltage transformation efficiency by utilizing what would otherwise be wasted energy, while maintaining a relatively simple circuit configuration compared to traditional high-gain converter topologies that require multiple active components and complex control circuits.
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 proposed converter design achieves high-gain voltage transformation efficiently, supporting a wide input voltage range, enhancing flexibility and resilience in DC power delivery, suitable for various applications including data centers and renewable energy systems, while maintaining simplicity and reducing costs.
Implementation Method 1
a primary winding of a first coupled inductor; a primary winding of a second coupled inductor connected in parallel with the primary winding of the first coupled inductor and in parallel with an input voltage
Implementation Method 2
an active clamp circuit including a third switch, a fourth switch, and a first capacitor
Implementation Method 3
a voltage multiplier cell including a secondary winding of the first coupled inductor, a secondary winding of the second coupled inductor, a second capacitor, a first diode, the first capacitor, and the third switch
Data Source
AI summary
Embodiments are disclosed of a multiphase converter that includes a main switch circuit, an active clamp circuit, a voltage multiplier cell, and an output capacitor. The main switch circuit includes a primary winding of a first coupled inductor; a primary winding of a second coupled inductor connected in parallel with the primary winding of the first coupled inductor and in parallel with an input voltage; a first switch connected between the primary winding of the first coupled inductor and the input voltage; and a second switch connected between the primary winding of the second coupled inductor and the input voltage. The active clamp circuit includes a third switch, a fourth switch, and a first capacitor. The voltage multiplier cell includes a secondary winding of the first coupled inductor, a secondary winding of the second coupled inductor, a second capacitor, a first diode, the first capacitor, and the third switch.