Matrix Transformer Topology for Integrated Onboard Charging and DC/DC Backup
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Solution Overview
Problem
The integration of battery current control modules (BCCMs) and inverter system controllers (ISCs) in automotive vehicles is challenging due to disconnecting circuitry, which increases the bill of materials and reduces package-level integration, making it unfavorable for reducing overall size and weight.
Innovation Solution
A matrix transformer structure with five windings and two separate cores is used to magnetically couple first and second isolated DC/DC converters, allowing for a bidirectional totem pole power factor correction circuit and integrating high voltage/low voltage DC/DC converters, enabling uninterrupted power supply even under single-point issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disconnecting circuitry is used to integrate BCCMs and ISCs, then power conversion function is achieved, but bill of materials increases and package-level integration is reduced
Solution Approach 1:
The patent merges the BCCM and ISC functions into a single integrated power conversion device. The power conversion circuit includes a first converter for converting first input voltage to first output voltage and a second converter for converting second input voltage to second output voltage, eliminating the need for separate disconnecting circuitry and achieving package-level integration while reducing bill of materials.
Solution Approach 2:
The integrated power conversion device performs multiple functions: it can convert first input voltage to first output voltage through the first converter, convert second input voltage to second output voltage through the second converter, and provide uninterrupted power delivery through bypass paths. This multi-functionality replaces what would otherwise require separate dedicated circuits for each function.
2Power
If matrix transformer structure with five windings and two separate cores is used, then power density increases and footprint reduces, but manufacturing complexity increases
Solution Approach 1:
The matrix transformer structure embeds multiple windings around shared cores in a nested configuration. The first and second converters share common magnetic cores, with windings arranged in a matrix pattern where multiple windings are coupled to the same cores. This nesting approach maximizes power density within a compact footprint while systematically organizing the complex winding structure.
3Ease of manufacture
If isolated DC/DC converters are magnetically coupled through shared transformer structure, then integration is improved, but reliability under single-point failures must be maintained
Solution Approach 1:
The power conversion circuit is segmented into independent first and second converters, each with its own input and output paths. The first converter converts first input voltage to first output voltage, while the second converter converts second input voltage to second output voltage. This segmentation allows uninterrupted power delivery: if one converter fails, the other can continue operating independently while still benefiting from magnetic coupling through the shared transformer structure.
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 integration reduces the overall footprint, increases power density, and ensures uninterrupted power delivery to low voltage loads even if one component fails, enhancing system efficiency and reliability.
Implementation Method 1
a matrix transformer structure, including five windings and two separate cores, shared between and magnetically coupling the first and second isolated DC/DC converters
Data Source
AI summary
An automotive power system has, among other things, a matrix transformer structure, including five windings and two separate cores, shared between and magnetically coupling a first isolated DC/DC converter arranged to directly exchange power with a traction battery and a second isolated DC/DC converter arranged to directly exchange power with a bus.