Phase-Shifted DC-DC Converter Dynamic Switching Control
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Solution Overview
Problem
Conventional DC-DC converters experience high switching losses and potential damage due to the reverse recovery effect in rectifier components when operating in a boost mode, particularly in electric vehicles with high-voltage systems, leading to inefficiencies and component degradation.
Innovation Solution
A DC-DC converter with a novel modulation method that controls semiconductor switches to minimize the reverse-recovery effect, using a transformer and active synchronous rectification to reduce switching losses, and a control device that adjusts switching times to manage current thresholds, thereby reducing power losses and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional DC-DC converters operate in boost mode with standard switching control, then power transmission capability is maintained, but switching losses increase and reverse recovery effect damages rectifier components
Solution Approach 1:
The patent implements dynamic switching control where the switching elements are operated in a non-fixed pattern. Specifically, the control device dynamically adjusts the switching timing based on current thresholds, creating variable switching intervals that adapt to operating conditions. This dynamic approach reduces reverse recovery effects and switching losses compared to conventional fixed-frequency switching.
Solution Approach 2:
The patent changes the switching parameters by controlling the switching elements to operate with variable duty cycles and timing. The control device modifies switching parameters (timing, duration, sequence) based on detected current levels, thereby changing the operational parameters of the rectifier components to minimize reverse recovery effects and reduce energy losses.
2Loss of energy
If switching elements are controlled to minimize reverse recovery effect, then power losses are reduced, but control complexity increases
Solution Approach 1:
The patent employs feedback control where the control device continuously monitors current through the switching elements and transformer secondary side. Based on this feedback information, the control device adjusts switching timing and duration to optimize performance. This feedback mechanism enables the system to automatically adapt switching parameters to minimize power losses while managing control complexity through intelligent algorithms.
Solution Approach 2:
The control system performs self-adjustment by automatically detecting current thresholds and modifying switching behavior accordingly. The system serves itself by using its own operational data (current measurements) to optimize its control strategy, reducing the need for external intervention or complex manual tuning while minimizing power losses.
3Loss of energy
If active synchronous rectification is used with adjusted switching times, then switching losses decrease, but device complexity increases
Solution Approach 1:
The patent implements dynamic switching control where the switching elements are operated in a non-fixed pattern. Specifically, the control device dynamically adjusts the switching timing based on current thresholds, creating variable switching intervals that adapt to operating conditions. This dynamic approach reduces reverse recovery effects and switching losses compared to conventional fixed-frequency switching.
Solution Approach 2:
The patent changes the switching parameters by controlling the switching elements to operate with variable duty cycles and timing. The control device modifies switching parameters (timing, duration, sequence) based on detected current levels, thereby changing the operational parameters of the rectifier components to minimize reverse recovery effects and reduce energy losses.
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 achieves lower switching losses, more efficient cooling, and a compact design, reducing the overall cost and electromagnetic compatibility issues while ensuring safe operation by minimizing the impact of the reverse recovery effect.
Implementation Method 1
a transformer (T) with a primary side and a secondary side. A first connection of the primary side of the transformer (T) is electrically coupled to the first node point (K1), and a second connection of the primary side of the transformer (T) is electrically coupled to the second node point (K2)
Implementation Method 2
a rectifier circuit (10) which is designed to rectify an electrical voltage between the third node point (K3) and a second connection of the secondary side of the transformer (T) and to provide the rectified voltage between a first output connection (A1) and a second output connection (A2)
Data Source
AI summary
The present invention relates to a DC-DC converter and to a method for controlling a DC-DC converter with high dielectric strength and reduced power losses. An optimized control of a potential-isolating multi-level half-bridge converter according to a phase-shifted full-bridge configuration with a novel modulation method is proposed.