Integrated Three-Phase LLC Magnetics for Current Sharing
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Solution Overview
Problem
Existing three-phase LLC and CLLC resonant converters face limitations in power conversion capability due to current stress on components and current sharing issues caused by tolerance of passive components.
Innovation Solution
The implementation of three-phase interleaved LLC and CLLC resonant converters with integrated magnetic structures, where the primary and secondary sides can be delta- or wye-connected, allowing for reduced RMS currents and minimized winding losses, and featuring integrated resonant inductors and transformers within a single magnetic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional three-phase LLC and CLLC resonant converters are used, then power conversion capability is limited, but component current stress and current sharing issues arise
Solution Approach 1:
The patent divides the three-phase converter into three separate single-phase LLC or CLLC resonant converter modules that operate in parallel. Each module handles one phase independently with its own resonant tank, transformer, and control circuitry. This segmentation allows each module to operate autonomously, eliminating current sharing issues between phases while collectively achieving high power conversion capability through the combined output of all three modules.
2Power
If higher power conversion capability is achieved, then component current stress increases, but this limits the converter design
Solution Approach 1:
By segmenting the high-power three-phase converter into three parallel single-phase modules, the total current is distributed across three separate current paths. Each component within a module handles only the current required for its phase, reducing peak current stress on individual components while maintaining high overall power conversion capability through the combined output of all modules.
3Loss of energy
If integrated magnetic structures are implemented, then winding losses are reduced, but device complexity increases
Solution Approach 1:
The patent combines the resonant inductor and transformer into a single integrated magnetic structure where the resonant inductor is formed as a leakage inductance of the transformer itself. This merging eliminates the need for separate magnetic components, reducing winding losses by minimizing inter-winding leakage and reducing the overall number of magnetic assemblies. The integrated design achieves energy efficiency while the modular three-phase architecture maintains manageable device 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 enhances power conversion efficiency by reducing winding losses and eliminating DC bias in the resonant capacitor, while also improving current sharing and overall system performance.
Implementation Method 1
transformer windings with integrated resonant inductors
Implementation Method 2
integrated resonant inductors and transformer windings with integrated magnetic structures
Data Source
AI summary
Three-phase interleaved resonant converters with integrated magnetics are described. In various examples, transformers are integrated into a transformer core of a converter. A primary side circuit includes a set of circuit segments corresponding to phases of the three-phase interleaved converter. Each of the circuit segments include an integrated winding component that provides a transformer primary winding and a resonant inductor connected in series.