Parallel DC/DC Power Supply Modules With Centralized PWM Control

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Solution Overview

Problem

Conventional DC/DC power supply systems face challenges in achieving high power density and efficiency while maintaining flexibility and compatibility, particularly in designs requiring higher power outputs, where increased leakage inductance and size issues lead to lower conversion efficiency and heat dissipation limitations, and result in higher costs and longer design periods due to repetitive labor investments.

Innovation Solution

A DC/DC power supply apparatus comprising multiple power boards and a control board, where the power boards are connected in parallel, with a feedback control circuit and PWM generator circuit on the control board to manage power distribution and heat dissipation, allowing for flexible control and optimized power output across multiple boards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a single DC/DC converter with greater power output is used, then the power output is improved, but the leakage inductance increases and conversion efficiency decreases

Engineering Contradiction:
Improvepower outputVSAvoidconversion efficiency
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The patent divides a single high-power DC/DC converter into multiple lower-power DC/DC converter modules connected in parallel. Each module has its own transformer and power devices, allowing the system to achieve high power output while maintaining low leakage inductance and high conversion efficiency in each individual module.

Inventive Principle:
Principle #1Segmentation

2Power

If a single DC/DC converter with greater power output is used, then the power output is improved, but the size of the transformer increases affecting wind channel design

Engineering Contradiction:
Improvepower outputVSAvoidtransformer size
Core Design Contradiction:
PowerVSVolume of moving object

Solution Approach 1:

The patent segments the single large transformer into multiple smaller transformers distributed across different converter modules. This reduces the size of each individual transformer, allowing for better wind channel design and heat dissipation while still achieving the required total power output through parallel connection of multiple modules.

Inventive Principle:
Principle #1Segmentation

3Power

If multiple board mounted power modules are connected in parallel, then the power output is improved, but the amount of control circuits increases causing cost increase

Engineering Contradiction:
Improvepower outputVSAvoidcontrol circuit amount
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent merges the control circuits of multiple DC/DC converter modules into a single centralized control circuit. This unified control circuit manages all power switches across the parallel-connected modules, reducing the total amount of control circuits needed while maintaining the high power output capability of the parallel configuration.

Inventive Principle:
Principle #5Merging (Combining)

4Power

If multiple board mounted power modules are connected in parallel, then the power output is improved, but the heat dissipation conditions vary causing efficiency limitations

Engineering Contradiction:
Improvepower outputVSAvoidheat dissipation conditions
Core Design Contradiction:
PowerVSTemperature

Solution Approach 1:

The patent segments the heat dissipation management by providing independent heat dissipation paths for each DC/DC converter module. This allows each module to operate in its own thermal environment, optimizing the efficiency of each module based on its specific heat dissipation conditions while collectively achieving high power output.

Inventive Principle:
Principle #1Segmentation

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 configuration enhances power density and efficiency, reduces manufacturing complexity and costs, and allows for flexible design and production, enabling higher power outputs while optimizing heat dissipation and reducing the need for redundant control circuits.

Implementation Method 1

each of the plurality of power boards 110 comprises a carrier circuit board 112 and a power device 114 disposed on the carrier circuit board 112

Methodology Applied
Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentUS9893625B2Direct current to direct current power supply apparatus
Publication Date: 2018.02.13 DELTA ELECTRONICS (SHANGHAI) CO LTD
  • US9893625B2 patent drawing
  • US9893625B2 patent drawing
  • US9893625B2 patent drawing

AI summary

Disclosed herein is a DC/DC power supply apparatus, which includes a plurality of power boards, a control board and a main board. The plurality of power boards are coupled in parallel with one another, and each power board includes a carrier circuit board and a power device disposed on the carrier circuit board. The control board includes a feedback control circuit and a PWM generator circuit; the feedback control circuit is configured to receive one or more feedback signals from the power boards; the PWM generator circuit outputs a PWM control signal to the power boards based on the feedback signal. The main board is electrically coupled to the power boards and the control board.