Resonant Converter Controller Optimizes Secondary Coil Discharge
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Solution Overview
Problem
Resonant converters are not perfectly efficient as they consume power during the conversion of DC power to output power, and secondary coils often do not fully discharge, leading to wasted energy and reduced efficiency.
Innovation Solution
A converter system with a controller that determines the energy level of an energy storage device and controls switching devices to remain closed until the output current reaches a discharge threshold, ensuring full discharge of the secondary coils and optimizing the duty cycle of switching devices based on phase angles to extend the discharge period until the output current is zero.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the switching device is opened early to protect against overcurrent, then device reliability is improved, but energy loss increases due to incomplete discharge of the secondary coil
Solution Approach 1:
The controller continuously monitors the current through the secondary coil and uses this feedback to determine when to open the switching device. By detecting the actual current state and comparing it to discharge thresholds, the system dynamically adjusts the switching timing to achieve complete energy discharge while preventing overcurrent conditions, thus resolving the contradiction between reliability and energy loss.
Solution Approach 2:
The controller is configured to open the switching device only after detecting that the secondary coil current has discharged to a predetermined threshold level. This preliminary condition checking ensures that the switching action occurs at the optimal moment - after sufficient energy has been extracted but before harmful overcurrent conditions develop - thereby simultaneously achieving energy efficiency and device protection.
2Loss of energy
If the switching device remains closed to allow full discharge, then energy efficiency is improved, but risk of overcurrent increases
Solution Approach 1:
The system uses real-time current monitoring feedback to dynamically control the switching device. The controller continuously measures the secondary coil current and automatically opens the switching device when the current reaches a safe threshold level, thus preventing overcurrent conditions while maximizing energy discharge efficiency. This feedback mechanism eliminates the need for conservative early switching.
Solution Approach 2:
The switching control strategy transitions from a static, predetermined switching time to a dynamic, condition-based control approach. The switching device remains closed as long as discharge conditions are favorable, and opens dynamically when current levels indicate either complete discharge or potential overcurrent risk. This dynamic adaptation optimizes efficiency while maintaining safety.
3Productivity
If the duty cycle is extended to maximize energy transfer, then productivity is improved, but device stress increases
Solution Approach 1:
The controller uses current feedback to dynamically adjust the duty cycle of the switching device. By monitoring the actual discharge current and comparing it to predetermined thresholds, the system extends the duty cycle to maximize energy transfer when conditions are favorable, and automatically reduces the duty cycle when current levels indicate approaching stress limits, thus optimizing productivity while protecting device strength.
Solution Approach 2:
The duty cycle control transitions from a fixed, static value to a dynamic, adaptive parameter that responds to real-time discharge conditions. The system dynamically extends the switching device closed position to maximize energy transfer efficiency, but automatically terminates the cycle when current thresholds indicate device stress risks, achieving optimal balance between productivity and device durability.
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 approach enhances the efficiency of resonant converters by ensuring that stored energy is fully discharged to the load, reducing power consumption and electrical losses, thereby improving overall converter efficiency.
Implementation Method 1
a transformer having a primary coil coupled to the primary-side circuit and at least one secondary coil coupled to the secondary-side circuit
Implementation Method 2
the secondary-side circuit including an energy storage device and at least one switching device configured to control a load current provided by the energy storage device to the load
Data Source
AI summary
According to aspects of the disclose, a converter system includes a primary-side circuit configured to be coupled to an energy source, a secondary-side circuit configured to be coupled to a load, the secondary-side circuit including an energy storage device and at least one switching device configured to control a load current provided by the energy storage device to the load, and a controller configured to be coupled to the primary-side circuit and the secondary-side circuit, the controller being further configured to determine a parameter indicative of an energy level of the energy storage device, and control, based on the parameter indicating that the energy level of the energy storage device is below a discharge energy level, the at least one switching device to be in an open and non-conducting position.