Modular Transformer Assembly for Scalable DC-DC Converter Power
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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 varying designs, which complicates the conversion of high direct voltage from power batteries to low-voltage power supplies for diverse vehicle models.
Innovation Solution
A modular transformer design that allows power rating adjustments by adding or removing conversion modules, with each module independently converting voltage and being interchangeable, reducing the need for multiple component designs and tools.
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 varying designs
Solution Approach 1:
The transformer is divided into a front-end assembly and multiple identical conversion modules in the back-end assembly. Each conversion module is an independent functional unit that can be individually added or removed. This segmentation allows the transformer to be configured for different power ratings by simply changing the number of conversion modules, eliminating the need for completely different designs for different vehicle models and reducing production and development costs.
Solution Approach 2:
The conversion modules are designed to be identical and interchangeable across different power ratings. The same conversion module design can be used for 1.2kW, 2.4kW, 3.6kW, and 4.8kW transformers by simply varying the number of modules. This universality reduces the need for multiple component designs, tools, and certifications, thereby reducing both production costs and development costs while maintaining adaptability to different load requirements.
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 device complexity increases due to non-interchangeable components and varying designs
Solution Approach 1:
The transformer is divided into a front-end assembly and multiple identical conversion modules in the back-end assembly. Each conversion module is an independent functional unit that can be individually added or removed. This segmentation allows the transformer to be configured for different power ratings by simply changing the number of conversion modules, eliminating the need for completely different designs for different vehicle models and reducing production and development costs.
Solution Approach 2:
The conversion modules are designed to be identical and interchangeable across different power ratings. The same conversion module design can be used for 1.2kW, 2.4kW, 3.6kW, and 4.8kW transformers by simply varying the number of modules. This universality reduces the need for multiple component designs, tools, and certifications, thereby reducing both production costs and development costs while maintaining adaptability to different load requirements.
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 modular design reduces production and development costs by enabling transformers to meet varying load requirements across different vehicle models with shared components and simple adjustments, while maintaining efficient voltage conversion.
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
Figure 1A
Figure 1B~2
Figure 3~4
AI summary
The present disclosure relates to a transformer (100) with a modular design, the transformer (100) comprising: a front-end assembly (10) comprising an input electrode (12) for receiving an input voltage; a back-end assembly (20) comprising an output electrode (22), for outputting an output voltage converted by the transformer (100); and a magnetic core (30), the magnetic core (30) being configured to assemble the front-end assembly (10) and the back-end assembly (20) together. The back-end assembly (20) comprises one or more conversion modules (20a), each conversion module (20a) being capable of independently converting the input voltage into the output voltage in collaboration with the magnetic core (30), and the power of the transformer (100) is the sum of the power of all the conversion modules (20a). The present disclosure further relates to a direct current-to-direct current converter comprising such a transformer (100), a vehicle comprising such a direct current-to-direct current converter, and a method for assembling such a transformer (100).