LLC Converter Design Automation for Frequency Range Optimization
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Solution Overview
Problem
Existing DC-to-DC power converter design techniques fail to adequately address the design parameters for switching frequency range, particularly for LLC converters, and lack automation support in electronic design automation tools, limiting their ability to achieve optimal voltage gain and efficiency.
Innovation Solution
A method and system for designing LLC power converters that calculate specific component values such as magnetizing inductance, resonant inductance, and capacitance based on given input and output parameters, including minimum and maximum switching frequencies, to ensure operation within a specified frequency range, reducing electromagnetic interference and switching losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If existing converter design techniques focus on achieving a particular voltage gain, then voltage gain is improved, but switching frequency range design parameters are neglected and automation is not supported
Solution Approach 1:
The patent transforms the design approach by changing from manual parameter selection to automated calculation of critical parameters (magnetizing inductance Lm, resonant inductance Lr, resonant capacitance Cr, and turns ratio n) based on input voltage range, output specifications, and desired switching frequency range. This enables EDA tools to automatically determine component values that satisfy both voltage gain and switching frequency range requirements simultaneously.
Solution Approach 2:
The patent replaces the manual iterative design process with an automated computational system implemented in EDA tools. The design methodology is encoded into algorithms that automatically calculate component parameters and evaluate performance, substituting the mechanical/manual design process with an automated software-based system that can be integrated into electronic design workflows.
2Adaptability or versatility
If LLC converters operate outside a specific frequency range, then design flexibility is increased, but electromagnetic interference and switching losses increase
Solution Approach 1:
The patent performs preliminary calculation of the resonant frequency fr and establishes it as a key design parameter before finalizing component values. By pre-determining the target resonant frequency based on the desired operating frequency range, the design ensures that the converter will operate within the optimal frequency band, preventing electromagnetic interference and excessive switching losses before the actual circuit is built.
Solution Approach 2:
The patent incorporates an evaluation step that checks whether the calculated component parameters produce the desired switching frequency range and performance characteristics. This feedback mechanism allows the design to be verified and adjusted, ensuring that the final implementation meets the frequency range specifications and avoids harmful electromagnetic effects.
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 solution enables LLC converters to operate efficiently within a defined frequency range, minimizing component size and interference, while allowing for automated design processes that optimize voltage gain and power density.
Implementation Method 1
a secondary winding magnetically coupled to the primary winding through a core of the transformer
Implementation Method 2
a resonant inductance Lr and a resonant capacitance Cr in series with the resonant inductance
Data Source
AI summary
An embodiment method for designing a power converter system includes receiving, by a processor, power converter design parameters. The design parameters include a minimum DC input voltage Vmin and a maximum DC input voltage Vmax, a minimum switching frequency fmin and a maximum switching frequency fmax of a switching bridge of the power converter, and a target output voltage and a target output power. The method also includes calculating, by the processor, a first power converter configuration. The first power converter configuration includes a calculated magnetizing inductance Lmc equal to Re tan(φ)(2πfmin)−1, where φ is a load angle complement equal to a sin(VminVmax−1), and Re is an equivalent reflected load resistance of the power converter. The first power converter configuration also includes a calculated resonant inductance Lrc equal to Lmc cos2(φ)(fmax2fmin−2−1)−1 and a calculated resonant capacitance Crc equal to Lrc−1(2πfmax)−2.