Power Converter With Orthogonal Secondary Windings

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Solution Overview

Problem

Existing power conversion systems, such as dual interleaved boost converters, face efficiency limitations when scaling up beyond the 1 kW range due to geometry constraints and eddy current losses, and inefficiencies in providing housekeeping power during standby periods.

Innovation Solution

A power conversion device with a magnetic core and multiple sets of windings, including a first set for primary operation and a third set that can be excited via both magnetic flux paths, using a composite magnetic structure with a mechanically soft material for reduced losses and orthogonal windings for efficient power transfer in both normal and standby modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If power conversion systems are scaled up beyond 1 kW range, then power throughput is improved, but efficiency deteriorates due to eddy current losses and geometry constraints

Engineering Contradiction:

Improvepower throughputVSAvoideddy current losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The magnetic core is divided into multiple segments with windings arranged in different orientations (first set with first orientation, second set with second orientation perpendicular to the first). This segmentation allows the system to handle higher power throughput while distributing eddy current losses across multiple smaller flux paths, thereby maintaining efficiency at multi-kW levels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces orthogonal magnetic flux paths by arranging windings in perpendicular orientations around the magnetic core. This dimensional change from single-axis flux to multi-axis flux enables the system to scale power throughput without proportionally increasing eddy current losses, as the magnetic fields are distributed across different spatial dimensions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Use of energy by stationary object

If primary windings are used to provide housekeeping power during standby periods, then control circuitry power is improved, but efficiency deteriorates due to switching component losses

Engineering Contradiction:

Improvehousekeeping powerVSAvoidswitching losses

Core Design Contradiction:

Use of energy by stationary objectVSLoss of energy

Solution Approach 1:

The third set of windings is designed to be excitable by both the first and second sets of windings, enabling it to serve dual functions: providing housekeeping power during standby periods when excited by one set, and contributing to main power output during normal operation when excited by both sets. This multi-functionality eliminates the need for separate power conversion components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own magnetic core and windings to generate housekeeping power during standby periods without requiring external power sources or separate conversion components. The third set of windings is self-excitable from the existing magnetic flux paths, allowing the control circuitry to power itself efficiently.

Inventive Principle:

Principle #25Self-service

3Device complexity

If multiple sets of windings are shared for power transfer, then device complexity is reduced, but manufacturing precision deteriorates due to coupling control requirements

Engineering Contradiction:

Improvenumber of power conversion componentsVSAvoidcoupling control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent employs asymmetric winding arrangements where the first and second sets of windings are oriented perpendicular to each other around the magnetic core. This asymmetric, orthogonal configuration naturally defines separate magnetic flux paths that reduce mutual interference and coupling control requirements, making the system more tolerant to manufacturing variations while still achieving efficient power transfer.

Inventive Principle:

Principle #4Asymmetry

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 enables scalable operation at multi-kW levels with reduced AC conductor losses, lower core losses, and minimized switching losses by utilizing a composite magnetic structure and orthogonal windings, enhancing efficiency and manufacturing tolerances.

Implementation Method 1

a first set of windings defining a first magnetic flux path, a second set of windings defining a second magnetic flux path magnetically orthogonal to the first magnetic flux path

Methodology Applied

Scientific EffectMagnetic flux: Magnetic Field

Implementation Method 2

Each winding of the third set of windings is configured to be excitable via both the first flux path and the second flux path

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS9224531B2Power converter using orthogonal secondary windings

Publication Date: 2015.12.29 BOSE CORP

AI summary

A power conversion device includes a magnetic core; and a plurality of windings surrounding portions of the magnetic core, including a first set of windings defining a first magnetic flux path, a second set of windings defining a second magnetic flux path magnetically orthogonal to the first magnetic flux path, and a third set of windings. Each winding of the third set of windings is configured to be excitable via both the first flux path and the second flux path.