Modular Power Converter Coil Layout for Magnetic Coupling Control
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Solution Overview
Problem
In power converters using multiple coils for transformation, changing circuits to meet customer specifications often requires readjustment of magnetic coupling degrees, which is not adequately addressed in existing technologies.
Innovation Solution
A power converter design where conversion circuits and coils are mounted on boards that can be easily replaced and positioned to adjust magnetic coupling, allowing for customizable circuit changes and magnetic coupling degree adjustments by modifying the board positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If circuits are changed to meet customer specifications, then adaptability is improved, but magnetic coupling degree readjustment becomes necessary which increases device complexity
Solution Approach 1:
The patent divides the power converter into modular components: a common board containing fixed circuits and a customized board containing customer-specific circuits. The customized board can be independently replaced without affecting the common board or requiring magnetic coupling readjustment, as the transformer core and coil positions are predetermined and fixed on the common board.
Solution Approach 2:
The common board serves as a universal platform that can support multiple different customized boards for various customer specifications. The predetermined transformer core and coil positions on the common board provide a universal interface that works with any customized board, eliminating the need for magnetic coupling readjustment when changing circuits.
2Manufacturing precision
If conversion circuits and coils are fixed on boards, then manufacturing precision is improved, but ease of manufacture deteriorates due to positioning requirements
Solution Approach 1:
The transformer core and coil positions are predetermined and pre-positioned on the common board during manufacturing. This preliminary action ensures precise relative positioning is built into the common board itself, so that when the customized board is later assembled, the magnetic coupling is already optimized without requiring additional positioning adjustments.
3Power
If multiple coils are used for power transformation, then power conversion capability is improved, but magnetic coupling degree control becomes more difficult
Solution Approach 1:
The patent enables dynamic adjustment of magnetic coupling by allowing the customized board to be positioned at different locations on the common board. Since the transformer core and coils are predetermined on the common board, moving the customized board changes the relative positions and thus the magnetic coupling degree between coils, providing dynamic control without complex adjustment mechanisms.
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
Enables easy replacement and positioning of conversion circuits and coils to meet customer requirements, ensuring optimal magnetic coupling for efficient power transmission and stabilization.
Implementation Method 1
a plurality of coils electrically connected to the respective power conversion circuits and wound around a transformer core
Data Source
AI summary
A power converter includes a plurality of ports provided to a housing, a plurality of conversion circuit electrically connected to the respective ports, and a plurality of coils electrically connected to the respective power conversion circuits and wound around a transformer core. The plurality of coils including a predetermined first coil electrically connected to a predetermined conversion circuit and a second coil. The conversion circuit is mounted to a predetermined board, while the first coil is fixed along the periphery of a board hole of the predetermined board. The predetermined board is fixed to the housing in the state in which the transformer core is inserted into the board hole to determine the position of the predetermined coil relative to the second coil.