Transformer-Isolated Motor Drive Circuit With Reduced PCB Complexity
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Solution Overview
Problem
Existing motor controllers have high structural complexity due to the large quantity of drive circuits required to provide drive voltages to switching transistors, leading to complex internal circuit layouts and increased costs.
Innovation Solution
A motor controller design that includes a bridge arm circuit with switching transistor bridge arms connected to motor windings, and a drive circuit with transformers, a primary-side switch, and a control unit, which provides drive voltages to switching transistors without the need for multiple control circuits and windings, thereby reducing structural complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plurality of drive circuits are used to provide drive voltages to switching transistors respectively, then each switching transistor can be driven independently, but the structural complexity of the drive circuit and motor controller increases significantly
Solution Approach 1:
The patent merges multiple drive circuits into a single integrated drive circuit that controls multiple switching transistors through a unified transformer structure. The primary side includes a common control unit and primary winding, while the secondary side has multiple independent windings that can provide isolated drive signals to different switching transistors, achieving both integration and independent control.
Solution Approach 2:
The drive circuit is designed with universal functionality to control multiple switching transistors using a single transformer. The transformer's multiple secondary windings can be configured to provide drive voltages to different switching transistors in the bridge arm circuit, allowing one drive circuit to perform the function of multiple separate drive circuits.
2Reliability
If multiple control circuits and windings are configured, then each switching transistor can be driven independently, but the required circuit board area and manufacturing costs increase
Solution Approach 1:
The patent combines multiple control circuits into a single integrated drive circuit with a unified transformer structure. The primary winding serves all switching transistors through a common control unit, while secondary windings provide isolated drive signals to individual transistors, significantly reducing the circuit board area required compared to multiple separate drive circuits.
3Device complexity
If a single transformer with multiple windings is used, then structural complexity is reduced, but the ability to provide isolated drive voltages to multiple switching transistors must be maintained
Solution Approach 1:
The transformer is segmented into multiple independent secondary windings, each capable of providing isolated drive voltages to different switching transistors. This segmentation maintains electrical isolation between control channels while being integrated into a single transformer structure, reducing overall complexity while preserving independent control capability.
Solution Approach 2:
The transformer acts as an intermediary device that provides electrical isolation between the primary control circuit and multiple secondary load circuits. Through magnetic coupling, it transfers energy and control signals while maintaining galvanic isolation, ensuring reliable independent drive voltages for multiple switching transistors.
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 proposed solution reduces the structural complexity of drive circuits and motor controllers, decreases the required circuit board area, and lowers costs by eliminating the need for numerous control circuits and windings, while ensuring accurate drive signal control through feedback voltage adjustments.
Implementation Method 1
the drive circuit includes a plurality of transformers, a primary-side switch, and a control unit. Specifically, a primary-side winding of each transformer includes a primary-side primary winding and a primary-side feedback winding. A secondary-side winding of each transformer is configured to output one drive voltage.
Data Source
AI summary
This application provides a motor controller, a drive circuit, a power device. The motor controller includes a bridge arm circuit and a drive circuit. The bridge arm circuit includes a plurality of switching transistor bridge arms. The drive circuit is configured to provide a plurality of drive voltages to a plurality of switching transistors of the bridge arm circuit respectively. The drive circuit includes a plurality of transformers, a primary-side switch, and a control unit. A primary-side winding of each transformer includes a primary-side primary winding and a primary-side feedback winding. A secondary-side winding of each transformer is configured to output one drive voltage. One end of each primary-side primary winding is configured to connect to a power supply. The other end of each primary-side primary winding is connected to an end of the primary-side switching transistor. The motor controller reduces structural complexity of the drive circuit.