Shared Filter Inductor Layout for Compact AC/AC Power Conversion
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Solution Overview
Problem
AC/AC power supplies with separate input and output filters require a large number of circuit elements and occupy significant volume, leading to high costs.
Innovation Solution
A power conversion device with a single filter inductor that includes multiple windings and a magnetic core, capable of performing both input and output filtering functions, reducing the number of windings and magnetic cores needed compared to conventional designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate input filter and output filter are used, then filtering performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the input filter inductor and output filter inductor into a single shared filter inductor with multiple windings. The first winding serves as the input filter inductor and the second winding serves as the output filter inductor, both sharing the same magnetic core. This merging reduces the total number of inductors and magnetic cores from two to one, thereby reducing device complexity and cost while maintaining filtering performance.
Solution Approach 2:
The shared filter inductor performs multiple functions simultaneously: it acts as both the input filter inductor and the output filter inductor. The first winding provides input filtering to reduce electromagnetic interference at the power grid side, while the second winding provides output filtering to ensure noise meets requirements for normal operation of the AC load. This multi-functionality eliminates the need for separate filter inductors.
2Reliability
If separate input filter and output filter are used, then filtering performance is improved, but volume occupied increases
Solution Approach 1:
By merging the input filter inductor and output filter inductor into a single shared inductor with multiple windings on a common magnetic core, the patent significantly reduces the volume occupied by filter components. Instead of requiring two separate inductors each with their own magnetic core, the design uses one shared magnetic core with multiple windings, thereby reducing overall filter volume while maintaining filtering performance.
3Reliability
If separate input filter and output filter are used, then filtering performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by merging two separate filter inductors into one shared filter inductor. This reduction in component quantity (from two inductors and two magnetic cores to one inductor with multiple windings and one magnetic core) directly lowers material costs, assembly costs, and overall circuit costs while maintaining the filtering performance required for both input and output sides.
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 effectively reduces circuit costs and volume by sharing inductor windings and magnetic cores, while maintaining filtering efficiency for AC/AC power supplies with single-phase or three-phase inputs and outputs.
Implementation Method 1
The AC/AC power supply filters high-frequency noise of an internal switch circuit by using the two filters
Implementation Method 2
The input filter is configured to make electromagnetic interference at a power grid side lower than a requirement limit, and the output filter is configured to make noise output by the AC/AC power supply meet a requirement for normal operation of an alternating current load
Data Source
AI summary
A power conversion device includes a first filter inductor and an AC/AC circuit, where the first filter inductor includes three inductor windings, and a first inductor magnetic core. The first inductor winding, the second inductor winding, and the third inductor winding are all wound around the first inductor magnetic core. The first inductor winding is connected to a first input end of the power conversion device, the second inductor winding is connected to a second input end and a second output end of the power conversion device, the first inductor winding and a second end of the second inductor winding are separately connected to the AC/AC circuit, the third inductor winding is connected to a first output end of the power conversion device, and the second inductor winding and a second end of the third inductor winding are separately connected to the AC/AC circuit.