Multi-Functional Inductor Single-Stage AC Power Converter
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Solution Overview
Problem
Existing AC powered converters require additional stages for Power Factor Correction (PFC), leading to increased size and cost, and there is a need for simpler, more efficient AC input power converters that can achieve near-ideal PFC.
Innovation Solution
A single-stage AC input power converter design that blends main and supplemental regulators using the same inductor or transformer winding, with actively managed energy storage for PFC, allowing power to move through a single stage and utilizing the same circuit elements for input current regulation and energy storage management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an extra stage of power conversion is added for Power Factor Correction, then Power Factor is improved to near-unity, but device complexity and size increase
Solution Approach 1:
The patent merges the main power conversion stage and the Power Factor Correction stage into a single integrated converter. The same inductor and switching elements are used for both functions, eliminating the need for separate PFC circuitry while achieving near-unity power factor.
Solution Approach 2:
The converter is designed with multi-functional components where the inductor serves dual purposes: power conversion and power factor correction. The switching network performs both voltage conversion and current shaping to achieve unity power factor, making each component serve multiple functions.
2Reliability
If an extra stage of power conversion is added for Power Factor Correction, then Power Factor is improved to near-unity, but cost increases
Solution Approach 1:
The patent merges the main power conversion stage and the Power Factor Correction stage into a single integrated converter. The same inductor and switching elements are used for both functions, eliminating the need for separate PFC circuitry while achieving near-unity power factor.
3Loss of energy
If power moves through a single stage, then efficiency is improved and size is reduced, but achieving near-ideal Power Factor becomes more difficult
Solution Approach 1:
The patent employs dynamic control of the switching network to adjust the converter's operation mode based on load conditions. The switching elements are controlled to achieve both efficient power conversion and current waveform shaping for unity power factor, with the control strategy adapting dynamically to maintain optimal performance.
Solution Approach 2:
The converter utilizes variable switching frequencies and duty cycles to optimize both efficiency and power factor. By dynamically changing operating parameters such as switching frequency and pulse width modulation ratios, the system achieves near-unity power factor while maintaining high efficiency in a single-stage configuration.
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 achieves near-ideal PFC and high efficiency by allowing power to move through a single stage, reducing size and cost while maintaining effective regulation and energy management.
Implementation Method 1
a multi-functional inductor on the output side of the power converter that supports both main regulation and supplemental regulation
Implementation Method 2
at least one multi-functional inductor on the output side of the power converter that supports both main regulation and supplemental regulation
Data Source
AI summary
In certain embodiments, a power converter has an input side connected to receive AC input power at an input node and an output side connected to produce a regulated output power at an output node. The power converter has a transformer having at least one primary winding on the input side and at least one secondary winding on the output side. The power converter has at least one multi-functional inductor that supports both main regulation and supplemental regulation in a time-multiplexed manner such that, during main regulation, input energy is transferred from the input node to the output node via the multi-functional inductor, and, during supplemental regulation, the stored energy is transferred from the at least one energy storage element to the output node via the multi-functional inductor. Depending on the embodiment, the multi-functional inductor(s) may be one or two secondary transformer windings or a separate buck inductor.