Power Conversion Device With Synchronous Switching Control
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Solution Overview
Problem
Existing power conversion devices face challenges with high voltage stress on switches and large magnetic elements, leading to poor performance and increased cost due to limited duty cycle and transformer turns, which restricts power density and efficiency.
Innovation Solution
A power conversion device design featuring two transformers with magnetically coupled primary and secondary windings, allowing for adjustable turn ratio and duty cycle, reducing volt-second on inductors and voltage stress on switches, and utilizing smaller magnetic components to enhance power density and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic-integrated hard-switching full-bridge converter is utilized to regulate the output voltage, then the circuit is simple and reliable, but the duty cycle is limited to be less than 0.5 and the size of the magnetic element and the voltage stress on the secondary switches cannot be further reduced
Solution Approach 1:
The patent applies dynamic switching control where the first and second switches are controlled to be turned on or off synchronously, and the third and fourth switches are controlled to be turned on or off synchronously. This dynamic coordination enables the duty cycle to exceed 0.5 while maintaining circuit reliability through synchronized switching states that prevent voltage stress on secondary switches.
Solution Approach 2:
The patent changes the switching parameter configuration by introducing a control mechanism that adjusts the duty cycle beyond the conventional 0.5 limit. Through parameter optimization of the switching时序 and voltage stress distribution, the system achieves extended duty cycle range while keeping magnetic element size manageable.
2Device complexity
If the turns ratio of transformer is adjusted to regulate output voltage, then the circuit is simple, but the large number of turns results in more PCB layers being required, thus leading to increased cost
Solution Approach 1:
The patent optimizes the transformer turns ratio parameters to achieve voltage conversion with fewer turns. By carefully selecting the turns ratio and combining it with the synchronous switching control, the system reduces the number of PCB layers required while maintaining simple circuit topology, thereby reducing manufacturing cost.
3Ease of manufacture
If two magnetic-integrated buck converters with 180 degrees out of phase are utilized, then the circuit can be easily implemented, but the duty cycle is too small and the voltage stress on the switch is high
Solution Approach 1:
The patent transitions from fixed 180-degree out-of-phase switching to dynamic synchronous switching control. The first and second switches are turned on or off synchronously, as are the third and fourth switches, enabling duty cycle adjustment beyond 0.5 while maintaining easy circuit implementation through coordinated switching states.
Solution Approach 2:
The patent changes the switching parameter configuration from conventional out-of-phase control to synchronized control with adjustable duty cycle. Through parameter optimization of the switching时序, the system achieves extended duty cycle range while keeping the circuit easy to implement.
4Loss of energy
If the bus voltage is stepped up from 12V to 54V to reduce bus loss and cost, then a bus converter is added to step down the voltage, but the voltage stress on switches and size of magnetic elements increase
Solution Approach 1:
The patent optimizes the voltage conversion parameters by using a transformer with specific turns ratio and synchronous switching control. This approach reduces the voltage stress on switches compared to conventional buck converters operating at high bus voltages, while still achieving efficient power conversion from 54V to 12V.
Solution Approach 2:
The patent uses smaller magnetic elements with fewer turns that can be manufactured more economically. By optimizing the transformer design with reduced turns and smaller core size, the system achieves cost-effective implementation while handling the 54V to 12V conversion efficiently.
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 voltage stress on switches and smaller magnetic components, enabling higher power density and efficiency while allowing for a wider range of input and output voltages, and reducing the number of PCB layers, thus improving the overall performance and cost-effectiveness of the power conversion device.
Implementation Method 1
Each transformer includes a primary winding and a secondary winding coupled to each other
Implementation Method 2
Two primary windings of the two transformers are magnetically coupled in series between the first primary node and the second primary node
Data Source
AI summary
The present disclosure provides a power conversion device including an input end having positive and negative input terminals, two bridge arms, two transformers and an output capacitor. Each bridge arm is connected to the input end in parallel, and includes three switches coupled in series. Two terminals of one switch are electrically connected to the positive input terminal and a primary node respectively. Two terminals of another switch are electrically connected to the negative input terminal and a secondary node respectively. Each transformer includes primary and secondary windings coupled to each other. Two primary windings are serially coupled between two primary nodes. Two secondary windings are serially coupled between two secondary nodes. Two terminals of the output capacitor are electrically connected to output positive and negative terminals respectively. The positive output terminal is coupled between the secondary windings, and the negative output terminal is coupled to the negative input terminal.