Multi-Winding Inductor for DC Power Line Communication

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing DC Power Line Communication (PLC) systems are inefficient in terms of component usage, prone to common mode interference, and costly due to the need for large transformer and inductor components, which occupy significant board space and reduce transmission efficiency.

Innovation Solution

A DC PLC system utilizing a first inductor with two secondary windings and one primary winding, magnetically coupled for efficient communication over a DC power line cable, allowing for smaller and less costly components, and improved transmission efficiency by decoupling DC power from AC communication signals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If transformer and inductor components are used to protect from common mode interference, then reliability is improved, but device complexity and board space increase

Engineering Contradiction:

Improveprotection from common mode interferenceVSAvoidnumber of transformer, capacitor and inductor components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated inductor component with multiple windings. The first inductor has a primary winding for power transmission and secondary windings for communication signals, eliminating the need for separate transformer and inductor components while maintaining protection against common mode interference through magnetic coupling between windings.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The first inductor serves multiple functions simultaneously: it provides magnetic coupling for communication signals, transmits DC power through the primary winding, and offers protection against common mode interference. This multi-functional component replaces what would traditionally require separate transformer, inductor, and capacitor components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If transformer and inductor components are used to protect from common mode interference, then reliability is improved, but board space increases

Engineering Contradiction:

Improveprotection from common mode interferenceVSAvoidboard space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate single-winding inductors and capacitors are used for signal decoupling, then communication functionality is improved, but device complexity and costs increase

Engineering Contradiction:

Improvesignal decoupling capabilityVSAvoidnumber of separate inductor and capacitor components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates the decoupling function directly into the first inductor through magnetic coupling between the primary and secondary windings. The magnetic field generated by the primary winding automatically decouples the power and communication signals for the secondary windings, eliminating the need for separate single-winding inductors and capacitors.

Inventive Principle:

Principle #5Merging (Combining)

4Weight of moving object

If DC power and AC communication signals are transmitted through the same conductors, then cable harness weight and cost are reduced, but susceptibility to common mode interference increases

Engineering Contradiction:

Improvecable harness weightVSAvoidcommon mode interference

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The first inductor acts as an intermediary component between the DC power source and the communication conductors. The magnetic coupling mechanism in the inductor isolates the common mode interference from the communication signals while allowing the dual-use conductors to carry both power and communication signals, thus protecting against interference despite the weight reduction benefits.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 significantly reduces board space and costs, enhances transmission efficiency, and provides robustness against common mode interference, enabling longer cable lengths and smaller product designs.

Implementation Method 1

the primary and secondary windings of the first inductor are magnetically coupled to enable magnetically coupled communication between the first transceiver and the two of the at least two conductors in the DC power line cable

Methodology Applied

Scientific EffectMagnetic coupling: Electromagnetic Induction

Data Source

PatentEP3863184B1System and method for improved DC power line communication

Publication Date: 2024.03.13 KOLLMORGEN CORP

Figure 1
Figure 2
Figure 3

AI summary

A device for communicating over a DC power line cable having at least two conductors is described. The device comprises a first inductor having two secondary windings and one primary winding. The device further comprises a first transceiver coupled to the primary winding of the first inductor. The two secondary windings of the first inductor are coupled on a first end to two of the at least two conductors of the DC power line cable and on a second end to a DC power supply. The second end of one of the two secondary windings of the first inductor is coupled to a DC voltage supply and the second end of the other of the two secondary windings is coupled to a DC power supply return to provide power to the DC power line cable. The primary and secondary windings of the first inductor are magnetically coupled to enable magnetically coupled communication between the first transceiver and the two of the at least two conductors in the DC power line cable.