Segmented Magnetic Core for Self-Excitation Push-Pull Converter
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Solution Overview
Problem
Self-excitation push-pull converters face inefficiencies due to magnetic saturation in their cores, particularly at low loads, rated loads, and high input voltages, making it difficult to increase working frequency and reduce losses.
Innovation Solution
A magnetic core design featuring a closed ring with a thick and thin part, where the thin part reaches saturation before the thick part, allowing for reduced energy consumption and increased efficiency by minimizing the time spent in saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a uniform magnetic core is used in self-excitation push-pull converters, then the circuit can operate with simple structure, but the converter efficiency is low especially at light loads due to excessive energy consumption during magnetic saturation
Solution Approach 1:
The magnetic core is divided into two distinct sections: a first magnetic core section with smaller cross-sectional area and a second magnetic core section with larger cross-sectional area. This segmentation allows different parts of the core to serve different functions - the smaller section saturates quickly to trigger oscillation while the larger section provides stable magnetic path, thereby reducing overall energy consumption during saturation cycles.
Solution Approach 2:
Different sections of the magnetic core are designed with different cross-sectional areas to create localized magnetic properties. The first section (smaller area) is optimized for rapid saturation to initiate push-pull oscillation, while the second section (larger area) maintains stable magnetic flux. This local differentiation reduces hysteresis losses and improves converter efficiency without complicating the overall structure.
2Loss of energy
If the number of coil turns is increased to reduce energy loss, then the converter efficiency improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention changes the magnetic path parameters by introducing unequal cross-sectional areas in different sections of the magnetic core. This parameter modification allows the system to achieve better energy efficiency through optimized magnetic flux distribution rather than simply increasing coil turns, thereby avoiding the manufacturing complexity associated with high-turn windings.
3Productivity
If the working frequency is increased to improve converter performance, then the conversion efficiency improves, but the energy loss during magnetic saturation increases significantly
Solution Approach 1:
By segmenting the magnetic core into sections with different cross-sectional areas, the invention enables the smaller section to saturate rapidly at high frequencies while the larger section maintains stable magnetic properties. This segmentation allows the converter to operate at higher working frequencies with reduced energy loss during saturation, improving overall productivity without excessive energy consumption.
4Stability of the object's composition
If a magnetic core with air gap is used to prevent saturation, then the magnetic core can operate in non-saturated state, but the self-excitation push-pull oscillation cannot be achieved
Solution Approach 1:
The segmented magnetic core structure allows the smaller first section to saturate and trigger oscillation while the larger second section prevents complete core saturation. This segmentation enables the system to achieve both self-excitation push-pull oscillation and stable operation without requiring air gaps, maintaining magnetic core integrity while ensuring reliable oscillation.
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 design enhances the efficiency of self-excitation push-pull converters across various loads, reduces the number of coil turns, and allows for higher working frequencies without significant loss increases, enabling the use of higher input voltages and improving overall conversion efficiency.
Implementation Method 1
the thin part can reach magnetic saturation before the thick part with the same increasing magnetic field excitation
Data Source
AI summary
A magnetic core for a transformer, which includes a closed ring with a thick part and a thin part. The thin part is magnetically saturated before the thick part when excited by the same increasing magnetic fields. The thin part only operates briefly at or near first quadrant saturation point or a third quadrant saturation point and, for the rest of the time, it operates in a state between the first quadrant saturation point and the third quadrant saturation point. The present invention overcomes the drawbacks of the conventional magnetic core for a self-excitation push-pull type converter, and significantly improves the efficiency of the converter when it is under a light load, and further improves its efficiency while under a rated load. As the number of turns of the coil on the magnetic saturation transformer is reduced, the working frequency of the converter is improved while still keeping the loss low.