Multi-Winding Transformer Interface for Series-Stacked Voltage Domains
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Solution Overview
Problem
Conventional power conversion architectures in modular energy systems, such as data centers and solar farms, are inefficient and bulky due to the need for numerous DC-DC converters, which increases power conversion stress and reduces power density.
Innovation Solution
A power conversion circuit utilizing a multi-winding transformer with DC-AC conversion units connected to each winding, coupled with a controller to regulate intermediate node voltages, enabling efficient conversion between DC and AC voltages and reducing the number of power conversion stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If numerous DC-DC converters are used to connect each device to the DC-link, then each device can be independently controlled and powered, but the system becomes bulky and inefficient with increased power conversion stress
Solution Approach 1:
The patent merges multiple DC-DC converter functions into a single multi-winding transformer by connecting multiple voltage domains in series. Each winding interfaces with a different voltage domain, allowing the single transformer to perform the power conversion function that previously required multiple separate converters, thereby reducing system complexity while maintaining device independence
Solution Approach 2:
The multi-winding transformer serves multiple functions simultaneously: it interfaces with multiple series-connected voltage domains, provides galvanic isolation, performs voltage transformation, and enables independent power delivery to each device. This universal component replaces the need for multiple specialized DC-DC converters
2Reliability
If each DC-DC converter is designed for full voltage rating and power rating, then each device receives adequate power, but the overall system efficiency decreases and power density is reduced
Solution Approach 1:
The patent segments the power conversion function across multiple windings of a single transformer, where each winding is optimized for its specific voltage domain rather than requiring each converter to handle the full voltage rating. This segmentation allows each winding to operate at optimal efficiency for its voltage level while collectively providing full power delivery capability
3Adaptability or versatility
If numerous DC-DC converters are deployed in the system, then comprehensive power management is achieved, but the physical size and volume of the system increase significantly
Solution Approach 1:
The patent combines multiple DC-DC converter units into a single integrated multi-winding transformer structure. By connecting the windings in series and interfacing with series-connected voltage domains, the system achieves comprehensive power management capability in a compact form factor, dramatically reducing the volume compared to using multiple separate converters
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 solution achieves high efficiency and power density by minimizing power conversion stress and component count, with a 10-port MAC-DPP prototype achieving 99.7% peak system efficiency and over 100 W/in3 power density.
Implementation Method 1
a multi-winding transformer including a magnetic core and a plurality of windings, where each DC-AC conversion unit is coupled to a corresponding winding of the multi-winding transformer
Data Source
AI summary
According to various embodiments, a power conversion circuit is disclosed. The power conversion circuit includes at least one DC bus. The power conversion circuit further includes a plurality of DC-AC conversion units coupled to the DC bus and configured to convert a DC voltage into an AC voltage. The power conversion circuit also includes a multi-winding transformer comprising a magnetic core and a plurality of windings, where each DC-AC conversion unit is coupled to a corresponding winding of the multi-winding transformer.