Multiphase Flyback Power Supply Asymmetric Transformer Design
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Solution Overview
Problem
Existing battery charging technologies lack real-time measurement and adjustment capabilities based on battery metrics, and they fail to efficiently handle high frequency power conversion, wide voltage variability, and bi-directional wireless control, leading to inefficiencies and limitations in power factor correction and transformer design.
Innovation Solution
The Multiphase Flyback Power Supply (MFPS) system, which includes a computer processor-controlled, high-frequency switching power supply with a phased array transformer design that adjusts output based on real-time battery metrics and uses wireless communication for control, providing efficient power factor correction and wide voltage variability, while minimizing transformer core losses through a unique transformer configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the switching frequency of the power supply is increased to reduce the size and cost of filter components, then the cost of inductive and capacitive components decreases, but technological limits on other power supply components prevent arbitrary frequency increases
Solution Approach 1:
The patent applies parameter changes by operating the power supply at an elevated switching frequency (e.g., 100 kHz or higher) compared to conventional frequencies. This frequency increase allows for smaller and less expensive filter components while the controller monitors and adjusts operational parameters to remain within technological limits of other components, thus resolving the contradiction between cost reduction and component limitations.
2Adaptability or versatility
If a single power supply channel is used, then the device complexity is reduced, but the power supply cannot meet high current demands or provide wide voltage variability required for universal battery charging
Solution Approach 1:
The patent merges multiple power supply channels into a single integrated device with a common controller and shared control logic. The controller manages multiple channels to provide wide voltage variability and high current capability while maintaining a unified device architecture, thus achieving adaptability without proportionally increasing overall device complexity.
Solution Approach 2:
The patent implements dynamic operation where the controller can independently adjust the output characteristics of each power supply channel in real-time. This dynamic control allows the system to adapt to different battery types, voltages, and current requirements, providing universal charging capability while maintaining manageable device complexity through intelligent control.
3Loss of energy
If traditional transformer placement is used, then the manufacturing process is simpler, but transformer core losses are not minimized
Solution Approach 1:
The patent employs asymmetric transformer placement where transformers are positioned in a non-uniform, optimized configuration rather than traditional symmetric arrangements. This asymmetric placement is specifically designed to minimize magnetic flux leakage and reduce core losses, accepting increased manufacturing complexity as a trade-off for improved energy efficiency.
Solution Approach 2:
The patent uses planar transformer designs that can be replicated and stacked in optimized configurations. By copying and stacking planar transformer units in specific arrangements, the system achieves minimized core losses through optimized magnetic coupling while maintaining manufacturing simplicity through standardized repeated units.
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 MFPS achieves efficient battery charging with improved power factor, reduced core losses, and enhanced reliability by dynamically adjusting output based on real-time metrics, supporting high current demands and wide voltage ranges, and enabling bi-directional communication for optimized battery management.
Implementation Method 1
The power conversion means may be a linear device such as a power supply using individual or multiple transformers that regulate the output voltage
Implementation Method 2
A power supply may be used within the Battery Industry as a battery charger, or as a means by which to charge an energy storage means, such as a capacitor used in the BattRecon Brand of de-sulfation devices
Data Source
AI summary
Improvements in a high frequency multiphase flyback power supply for battery charging and power supplies used in devices that provide de-sulfation capability to the batteries. The system utilizes a high efficiency, multiphase array flyback battery charger or power supply, with a localized or Internet based bi-directional communication means to monitor and optimize battery charging. The de-sulfating current can be a variable, or harmonic, repeating patterns of ON and OFF pulses which may be applied to the battery at an operator-adjustable peak amperage of about 0-350 amps. The de-sulfation process before, during or after the normal battery charging cycle, or any combination thereof. The temperature of the battery and the specific gravity of the fluid within the battery is measure during the de-sulfating process. The connection to the internet allows the processes to be monitored at a distance from where the charging is taking place.