Matrix Transformer Winding Layout for Non-Integer Turn Ratios
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Solution Overview
Problem
Matrix transformers face inefficiencies and reduced voltage adjustment ranges when the ratio of the high-voltage-side winding turn quantity design value to the number of sub-transformers is not an integer, requiring adjustments that deviate from ideal transformer ratios.
Innovation Solution
The solution involves arranging first windings in series and second windings in parallel across sub-transformers with unequal turn quantities or layer configurations, ensuring the magnetic inductance ratio matches the turn quantity ratio, allowing for equal voltage division and maintaining efficiency and voltage adjustment range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the total turn quantity of the high-voltage-side winding is adjusted to be an integer multiple of the sub-transformer quantity for equal division, then the winding can be equally divided among all sub-transformers, but the transformer ratio deviates from the design value, reducing efficiency and voltage adjustment range
Solution Approach 1:
The high-voltage-side winding is segmented into multiple first windings with different turn quantities, where each first winding is wound on a separate magnetic core column. This segmentation allows the sum of turn quantities to equal the design value (11 turns) without requiring equal division, thereby maintaining the transformer ratio while still achieving manufacturability through modular winding construction.
2Ease of manufacture
If the total turn quantity of the high-voltage-side winding is adjusted to be an integer multiple of the sub-transformer quantity for equal division, then the winding can be equally divided among all sub-transformers, but the voltage adjustment range is reduced
Solution Approach 1:
Different magnetic core columns are assigned first windings with different turn quantities (3, 3, 3, 2 turns respectively), creating local variations in winding characteristics. This local quality differentiation allows the overall transformer to achieve the design turn quantity of 11 while maintaining flexibility in voltage adjustment, as each segment can be optimized for its specific function.
3Manufacturing precision
If the turn quantity design value is not an integer multiple of the sub-transformer quantity, then the ideal transformer ratio can be maintained, but the winding cannot be equally divided among all sub-transformers
Solution Approach 1:
The first windings on different magnetic core columns are deliberately made asymmetric in turn quantity (3, 3, 3, 2 turns instead of equal 3-turn windings). This asymmetric configuration resolves the contradiction by allowing the total turn quantity to precisely match the design value of 11, thereby maintaining manufacturing precision for the transformer ratio while accepting that equal division is not possible.
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 approach ensures normal operation and performance of the matrix transformer by matching the actual turn quantity of the high-voltage-side winding with the design value, maintaining efficiency and voltage adjustment capabilities without sacrificing performance.
Implementation Method 1
Each magnetic core column is wound with a first winding and a second winding. First windings are connected in series to form a high-voltage-side winding, and second windings are connected in parallel to form a low-voltage-side winding.
Data Source
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AI summary
This application discloses a matrix transformer, a power converter, and a matrix transformer winding arrangement method. Each of magnetic core columns of n sub-transformers of the matrix transformer is wound with a first winding and a second winding, first windings are used to form a high-voltage-side winding of the matrix transformer, and second windings are used to form a low-voltage-side winding of the matrix transformer. A ratio of a turn quantity design value of the high-voltage-side winding to the quantity n of the sub-transformers is not an integer. However, a total quantity of actually wound turns of the high-voltage-side winding matches the turn quantity design value by arranging windings with unequal turn quantities on different sub-transformers or arranging windings on sub-transformers in layers, so that efficiency and a voltage adjustment range of the matrix transformer do not need to be sacrificed. Under a condition that turn quantities of the second windings of the n sub-transformers are equal, voltages corresponding to the second windings are equal, so that the second windings can be directly connected in parallel for use. In this way, normal use performance of the matrix transformer is ensured.