Multi-Tapped Autotransformer for Zero-Voltage Switched-Capacitor Conversion
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Solution Overview
Problem
Conventional switched-capacitor DC-DC converters face inefficiencies due to hard switching, which can be mitigated by incorporating an inductor in each stage, but this does not fully address power conversion efficiency issues, especially in applications requiring efficient voltage conversion across a wide range like 40 VDC to 60 VDC.
Innovation Solution
A multi-tapped autotransformer with specific winding configurations and magnetic core designs is used to enhance power conversion efficiency by providing zero voltage switching and reducing switching losses, allowing for efficient generation of output voltages in power supply circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an inductor is placed in series with each capacitor in each stage of the switched-capacitor converter, then hard switching is mitigated and resonant switching is achieved, but device complexity increases and power conversion efficiency is not fully improved
Solution Approach 1:
The patent combines multiple inductors into a single shared inductor that serves all capacitor stages simultaneously. This merging approach maintains the resonant switching benefits for each stage while eliminating redundant components, thereby reducing device complexity without sacrificing the mitigation of hard switching losses.
Solution Approach 2:
The shared inductor performs multiple functions: it provides resonant switching for each capacitor stage, stores energy for multiple stages, and enables zero-current switching across all stages. This multi-functionality reduces the overall component count while maintaining the energy loss mitigation benefits.
2Adaptability or versatility
If conventional switched-capacitor converters are used with wide voltage range (40 VDC to 60 VDC), then adaptability is improved, but power conversion efficiency deteriorates due to hard switching
Solution Approach 1:
The patent implements dynamic switching control that adapts the resonant frequency and switching timing based on the input voltage level. This dynamic adjustment enables the converter to maintain zero-current switching conditions across the wide voltage range from 40 VDC to 60 VDC, preserving power conversion efficiency while accommodating voltage variations.
Solution Approach 2:
The converter dynamically changes operating parameters including switching frequency, duty cycle, and resonant frequency based on the detected input voltage level. These parameter adjustments ensure that the resonant tank circuits operate at optimal conditions across the entire voltage range, preventing hard switching losses while maintaining adaptability.
3Loss of energy
If multiple inductors are used in each stage to achieve resonant switching, then switching losses are reduced, but power density and device complexity increase
Solution Approach 1:
The patent merges multiple stage-specific inductors into a single shared inductor that serves all resonant tank circuits. This consolidation reduces the total inductance volume and component count, thereby improving power density while maintaining the resonant switching mechanism that reduces switching losses.
Solution Approach 2:
Instead of physically replicating inductors for each stage, the patent uses a single shared inductor that is effectively 'copied' or reused across multiple resonant tank circuits through clever circuit topology. This approach maintains the functional benefits of multiple inductors while achieving the space and power density benefits of a single component.
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 improved power conversion efficiency and power density by enabling zero voltage switching and reducing overall winding losses, making it suitable for a wide range of voltage conversion applications.
Implementation Method 1
The core conveys the energy from the first windings to the second windings to produce an output voltage
Data Source
AI summary
An apparatus comprises: first windings, second windings, a magnetic core, and multiple tap nodes. The first windings are primary windings of a multi-tapped autotransformer. The second windings are secondary windings of the multi-tapped autotransformer. The first windings and the second windings are wrapped around the magnetic core, the second windings disposed in a series connection between the first windings. The multiple tap nodes providing coupling of the first windings and the second windings to a power supply circuit such as a switched-capacitor converter.