Shared Flyback Transformer for Redundant Power Steering
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Solution Overview
Problem
Existing electric power steering systems face challenges in providing a reliable power supply to the motor without increasing component count and board area, as existing fail-safe units require synchronization and redundancy, leading to higher costs and space usage.
Innovation Solution
The implementation of a redundant power supply system using two power supply units with a shared flyback transformer having a magnetic core with independent air gaps, allowing each unit to operate independently and reducing costs and space by sharing the magnetic core, while ensuring continuous power delivery to the electric motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two completely independent power supply units are used to ensure redundancy, then reliability is improved, but device complexity and cost increase due to needing synchronization units and multiple components
Solution Approach 1:
The patent combines two power supply units into a single integrated flyback transformer structure, where both units share a common magnetic core. This merging reduces the total component count and simplifies the overall device while maintaining the redundancy needed for reliable operation. The synchronization unit requirement is eliminated because the shared core architecture inherently coordinates the two power supply units.
Solution Approach 2:
The magnetic core serves multiple functions simultaneously: it provides magnetic coupling for both power supply units, acts as an energy storage element for both units, and enables automatic synchronization between the two units. This multi-functionality reduces the need for separate synchronization components and reduces overall device complexity.
2Reliability
If redundant power supply units are implemented, then reliability is improved, but board area and manufacturing cost increase due to multiple components
Solution Approach 1:
The patent merges two separate power supply units into a single integrated transformer structure, significantly reducing the board area required. By sharing the magnetic core and using common winding structures, the physical footprint is minimized while maintaining full redundancy capability for reliable operation.
3Device complexity
If a shared magnetic core is used to reduce component count, then device complexity is reduced, but reliability may worsen due to potential coupling between power supply units
Solution Approach 1:
The patent segments the magnetic core into distinct magnetic paths for each power supply unit using magnetic shields or gaps. This segmentation prevents magnetic coupling and cross-interference between the two units while they share the common core structure, thereby maintaining reliability and independence despite the reduced component count.
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 solution ensures reliable power supply to the electric motor by decoupling the redundant power supply units, reducing component costs and space, and maintaining motor functionality even in case of failure, while minimizing the impact of shared magnetic core usage.
Implementation Method 1
two power supply units 1A, 1B with a shared flyback transformer 16 having a magnetic core 24
Data Source
AI summary
An electromechanical motor vehicle power steering mechanism may include an electric motor and a control unit. The electric motor may be configured to provide a steering assist force. The control unit may be configured to control a current to the electric motor. Further, the control unit may include two redundant power supply units. Each of the two redundant power supply units may be connected to a vehicle battery. Also, the two power supply units may each comprise a primary winding and a secondary winding as part of a flyback transformer with a shared iron core. The shared magnetic core may be E-shaped with a middle leg and two side legs. The primary winding and the secondary winding of one of the two redundant power supply units may be wound around a first of the two side legs.