Modular Matrix Transformer Layout for High-Current DC-DC Conversion
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Solution Overview
Problem
Conventional single-stage DC-DC power supplies face challenges in high output current and low voltage applications, characterized by high losses, poor heat dissipation, and low-frequency oscillations, which limit efficiency and system stability, and modular transformer solutions suffer from unstable magnetic flux coupling and increased production costs.
Innovation Solution
A DC-DC power supply with a modular transformer assembly featuring a novel flux cancellation scheme and modular matrix transformer, utilizing a primary circuit and secondary circuit connected through M transformer sets, where each transformer includes series-connected primary and secondary windings, arranged in a specific layout to achieve flux cancellation and reduced ripple flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single large transformer is used for energy conversion in high output current applications, then the power conversion capability is improved, but energy losses increase and heat dissipation performance deteriorates
Solution Approach 1:
The patent divides a single large transformer into multiple smaller transformer modules (e.g., three-phase modular structure). Each module handles a portion of the total power, enabling better heat dissipation and reduced core losses while maintaining high power conversion capability through parallel operation of multiple modules.
2Power
If a single large transformer is used for energy conversion, then the power conversion capability is improved, but heat dissipation performance deteriorates
Solution Approach 1:
By segmenting the transformer into multiple smaller modules with independent magnetic cores and winding sets, each module generates less heat and has improved surface area to volume ratio, significantly enhancing heat dissipation performance while maintaining high power conversion capability.
3Loss of energy
If modular transformer architectures are adopted to reduce losses, then energy efficiency is improved, but magnetic flux coupling stability deteriorates
Solution Approach 1:
The patent combines multiple modular transformer units with identical magnetic flux characteristics into a unified three-phase system. The modular structure maintains stable magnetic flux coupling through synchronized operation and coordinated control of primary and secondary windings across modules, achieving both energy efficiency and flux stability.
4Loss of energy
If modular transformer architectures are adopted, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The patent designs universal modular transformer units that can be configured in different phase arrangements (single-phase, three-phase, etc.). Each module serves multiple functions including power transformation, heat dissipation, and magnetic flux management, reducing overall system complexity despite the modular architecture.
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
The solution provides scalability, enhanced efficiency, and reduced core volume, minimizing low-frequency oscillations and core losses, suitable for high output current applications.
Implementation Method 1
M transformer sets electrically connected in parallel between the primary circuit and the secondary circuit. Each of the M transformer sets includes N transformers... Each transformer includes a first primary winding, a second primary winding, a first secondary winding and a second secondary winding
Implementation Method 2
The first and second primary windings of the N transformers in each of the M transformer sets are electrically connected in series
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A DC-DC power supply (1) and a transformer assembly are provided. The DC-DC power supply (1) includes primary and secondary circuits (11, 12) and M transformer sets electrically connected in parallel between the primary and secondary circuits (11, 12). Each transformer set includes N transformers (TR1, TR2), where M and N are positive integers. Each transformer (TR1) includes first and second primary windings (P11, P12) and first and second secondary windings (S11, S12). A connection node of the first and second secondary windings (S11, S12) is electrically connected to an output capacitor (Co) of the secondary circuit (12), and each secondary winding (S11, S12) is electrically connected to a corresponding secondary switch (SR11, SR12) of the secondary circuit (12). The first and second primary windings (P11, P12) in each transformer set are electrically connected in series. All transformers (TR1, TR2) are arranged along a first direction (X), and each transformer (TR1) includes a first side column (101), a center column (103) and a second side column (102) arranged along the first direction (X) with each extending along a second direction (Y) perpendicular to the first direction (X).