Modular Transformer Architecture for Scalable DC-DC Power Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing transformer designs for new-energy vehicles require different power ratings, leading to increased production and development costs due to non-interchangeable components and varied designs, which complicates the conversion of high direct voltage from power batteries to low-voltage power supplies for varying load demands.
Innovation Solution
A modular transformer design that allows power rating adjustments by adding or removing conversion modules, with each module independently converting voltage, enabling the transformer to meet different load requirements without the need for cooperative module interactions, thus reducing production and development costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different transformer designs are used for different power ratings, then the transformer can meet the specific load requirements of different vehicle models, but the production costs and development costs increase due to non-interchangeable components and varied designs
Solution Approach 1:
The transformer is divided into a standardized front-end assembly and multiple interchangeable conversion modules in the back-end assembly. Each conversion module is an independent functional unit that can be selectively assembled. This segmentation allows the transformer to be configured for different power ratings by simply changing the number of conversion modules, while the front-end assembly remains standardized across all models, thereby reducing production costs through component commonality.
Solution Approach 2:
The front-end assembly is designed as a universal component that can be used across all transformer models regardless of power rating. The conversion modules are also designed with universal interfaces and mounting structures. This universality enables a single front-end assembly design to serve multiple vehicle models, and conversion modules to be interchangeable across different power ratings, significantly reducing development costs and manufacturing complexity.
2Adaptability or versatility
If different transformer designs are used for different power ratings, then the transformer can meet the specific load requirements of different vehicle models, but the development costs increase due to the need to create designs and obtain certifications for each transformer
Solution Approach 1:
By segmenting the transformer into a standardized front-end assembly and interchangeable conversion modules, the design complexity is reduced. The front-end assembly requires only one design and certification, while conversion modules use standardized designs that can be certified once and reused across multiple models. This segmentation eliminates the need to create entirely new designs for each power rating.
Solution Approach 2:
The universal front-end assembly design and standardized conversion modules enable one design to serve multiple functions across different power ratings. The standardized interfaces, mounting structures, and electrical connections allow the same design to be applied universally, reducing the number of unique designs and certifications needed.
3Reliability
If traditional transformer designs are used, then each transformer is optimized for its specific power rating, but the components are not interchangeable and require different tools for production
Solution Approach 1:
The segmentation into standardized front-end assembly and modular conversion modules allows each module type to be produced using the same tools and processes. The standardized interfaces and mounting structures ensure that the same manufacturing equipment can produce components for all power ratings, eliminating the need for different tools.
Solution Approach 2:
The universal design of conversion modules with standardized mounting portions, electrical connections, and structural features enables them to be manufactured using the same tooling and processes regardless of the final transformer power rating. This universality allows a single set of manufacturing tools to produce components for all models.
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 modular design enables cost-effective production and flexibility in meeting diverse power supply needs across different vehicle models by allowing easy adjustment of power ratings through module addition or removal, enhancing efficiency and reducing manufacturing complexity.
Implementation Method 1
a magnetic core configured to assemble the front-end assembly and the back-end assembly together. The back-end assembly comprises one or more conversion modules, each conversion module being capable of independently converting the input voltage into the output voltage in collaboration with the magnetic core
Data Source
AI summary
The present disclosure relates to a transformer with a modular design, the transformer comprising: a front-end assembly comprising an input electrode for receiving an input voltage; a back-end assembly comprising an output electrode, for outputting an output voltage converted by the transformer; and a magnetic core, the magnetic core being configured to assemble the front-end assembly and the back-end assembly together. The back-end assembly comprises one or more conversion modules, each conversion module being capable of independently converting the input voltage into the output voltage in collaboration with the magnetic core, and the power of the transformer is the sum of the power of all the conversion modules. The present disclosure further relates to a direct current-to-direct current converter comprising such a transformer, a vehicle comprising such a direct current-to-direct current converter, and a method for assembling such a transformer.