Modular DC/DC Converter with Interleaved Phase-Shift Control
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Solution Overview
Problem
Existing DC-to-DC converters face challenges in efficiently integrating low voltage power sources, such as fuel cell stacks or batteries, with aircraft electric power distribution systems that require regulated dual polarity and high voltage levels for powering DC loads and voltage source inverters.
Innovation Solution
The use of interleaved phase-shift modulation signals to control voltage converter cells, each comprising a transformer with a primary and secondary side, a full-bridge converter connected in parallel, and center-tapped rectifiers in series, allowing for high power and high voltage boost ratio conversion, enabling the integration of low voltage sources into aircraft systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional DC-to-DC converters are used to integrate low voltage power sources with aircraft electric power distribution systems, then the system can operate with standard voltage levels, but the converter size, weight, and complexity increase significantly to achieve the required high voltage boost ratio and power level
Solution Approach 1:
The converter architecture is segmented into multiple identical modular units, each comprising a full-bridge converter, transformer, and center-tapped rectifier. These modules are connected in parallel on the primary side and series on the secondary side, allowing the system to achieve high power and high voltage through modular scaling rather than requiring a single complex converter design.
Solution Approach 2:
The patent transitions from a single-stage converter to a multi-stage modular architecture by adding spatial dimensions (multiple parallel modules) and temporal dimensions (interleaved phase-shifted operation). This dimensional expansion allows the system to achieve high voltage boost ratios and power levels without proportionally increasing the complexity of individual converter stages.
2Power
If a single-stage high voltage boost converter is designed to achieve high voltage conversion ratio, then the voltage transformation is accomplished in one stage, but the input current ripple and output filter size increase significantly
Solution Approach 1:
The patent employs periodic interleaved operation of multiple converter modules with phase-shifted control signals. Each module operates periodically with a phase shift relative to others, causing their current ripples to cancel each other out through constructive and destructive interference, thereby reducing the overall input current ripple while maintaining high voltage boost ratio.
3Power
If high power conversion is achieved using conventional converter topologies, then the required power level is attained, but the primary switch stress and device reliability issues increase
Solution Approach 1:
The high power conversion task is segmented across multiple parallel converter modules, distributing the current and power stress among multiple primary switches rather than concentrating it in a single switch. This segmentation reduces the stress on each individual switch, improving reliability and allowing the use of smaller, more reliable semiconductor devices.
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 solution achieves a high power conversion with a high voltage boost ratio, reducing input current ripple and output filter size, minimizing primary switch stress, and optimizing the converter architecture for high power applications.
Implementation Method 1
a transformer comprising a primary side and a secondary side
Implementation Method 2
a full-bridge voltage converter connected in parallel to the primary side
Implementation Method 3
center-tapped rectifiers connected in series to the secondary side
Data Source
AI summary
A voltage conversion system and methods are disclosed. Voltage converter cells are controlled using interleaved phase-shift modulation signals, and convert an input electrical current at an input voltage to an output electrical current at an output voltage. Each of the voltage converter cells comprises: a transformer comprising a primary side and a secondary side, a full-bridge voltage converter connected in parallel to the primary side, and center-tapped rectifiers connected in series to the secondary side. One or more group of outputs of the voltage converters are coupled in series via the center-tapped rectifiers.