Pulsed Rectifier Architecture Reducing Diode Losses
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Solution Overview
Problem
Conventional power rectifiers suffer from high diode losses, current imbalance, and reactor saturation, leading to reduced efficiency and difficulty in controlling output voltage, especially at low loads, due to complex transformer winding schemes and the need for air-gapped cores.
Innovation Solution
The rectifier system employs a novel configuration with current paths including only two diodes not directly connected to the output, reducing diode losses and mitigating reactor saturation by alternately conducting output reactors, which simplifies design and improves load balancing without requiring air-gapped cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional rectifier configurations are used with complex transformer winding schemes, then power conversion capability is achieved, but diode losses increase and reactor saturation occurs
Solution Approach 1:
The rectifier system is divided into multiple independent rectifier legs (first, second, third, and fourth legs) with separate diode bridges and reactors. Each leg operates semi-independently, allowing current to be distributed across multiple paths. This segmentation reduces the current burden on individual diodes and reactors, thereby reducing diode losses and preventing reactor saturation while maintaining overall power conversion capability.
Solution Approach 2:
The patent introduces intermediate coupling reactors and DC capacitors as mediators between the diode bridges and the load. These intermediaries smooth current fluctuations and balance the load distribution across different rectifier legs, reducing peak currents through individual diodes and preventing reactor saturation. The DC capacitors specifically act as energy buffers that decouple the rectifier stages from the load.
2Manufacturing precision
If conventional rectifier configurations are used, then power conversion is achieved, but current imbalance and reactor saturation occur leading to difficulty in controlling output voltage at low loads
Solution Approach 1:
The rectifier system employs dynamic current distribution across multiple rectifier legs with alternating conduction patterns. The first and second diode bridges alternate conduction in the first and second reactors, while the third and fourth diode bridges alternate conduction in the third and fourth reactors. This dynamic switching and alternating conduction ensures balanced current distribution and prevents reactor saturation even at varying load conditions, enabling accurate output voltage control at low loads.
Solution Approach 2:
The patent changes the operational parameters of the rectifier system by introducing multiple independent rectifier legs with alternating conduction. Each leg operates with controlled current parameters, and the system dynamically adjusts the conduction timing and current distribution across legs. This parameter control prevents any single reactor from saturating and maintains stable output voltage across the full load range including low load conditions.
3Productivity
If simple rectifier configurations are used, then device complexity is reduced, but diode losses increase and efficiency decreases
Solution Approach 1:
The rectifier system segments the power conversion function into multiple parallel legs with separate diode bridges and reactors. This segmentation distributes the total current across multiple diode paths, reducing the current through each individual diode and thereby reducing diode conduction losses. The segmented architecture achieves higher overall efficiency without requiring complex control mechanisms.
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 reduces diode losses by 33% and significantly mitigates reactor saturation, enabling more accurate output voltage control at low loads and improving overall power conversion efficiency.
Implementation Method 1
providing the input AC power to at least a first diode bridge and a second diode bridge and at least a first set of diodes and a second set of diodes to generate Direct Current (DC) power
Implementation Method 2
providing, by the at least first diode bridge and the second diode bridge and the at least first set of diodes and the second set of diodes, the DC power to the at least one output reactor (308), and providing, by the at least one output reactor, the DC power to an output
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
According to one aspect of the present disclosure, a method is provided including acts of receiving input Alternating Current (AC) power, providing the input AC power to at least one diode bridge to generate Direct Current (DC) power, providing, by the at least one diode bridge, the DC power to at least one set of diodes, providing, by the at least one set of diodes, the DC power to at least one output reactor, and providing, by the at least one output reactor, the DC power to an output.