Shared-Magnetic Transformer Layout for Compact High-Voltage DC Conversion
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Solution Overview
Problem
Existing power converters face challenges in achieving miniaturization for high-voltage and high-capacity DC/DC conversion due to the need for a large number of transformers, which increases size and complexity.
Innovation Solution
A power converter design that utilizes a multiple transformer configuration with shared magnetic paths among primary and secondary windings, allowing for series or parallel connections of DC/AC and AC/DC converters, and employs a magnetic circuit model with bypass iron cores to minimize size and prevent cross-currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high number of DC/AC transformers are arranged in parallel on the primary side to obtain current capacity for high-voltage high-capacity DC/DC conversion, then the current capacity is improved, but the device size increases due to the arrangement of a high number of multiple transformers
Solution Approach 1:
The patent merges multiple primary windings and multiple secondary windings into a single multiple transformer structure with shared magnetic paths. This consolidation allows the system to achieve high current capacity through parallel connection of DC/AC converters while reducing the overall device size by eliminating the need for separate transformer units for each converter.
Solution Approach 2:
The multiple transformer is designed with a shared magnetic core that serves multiple functions simultaneously - it provides magnetic coupling for multiple primary windings and multiple secondary windings, enables DC/DC conversion, and reduces device footprint. This multi-functional design allows a single transformer structure to replace what would traditionally require multiple separate transformers.
2Power
If the turn ratios of transformers are increased to obtain the required step-up ratio, then the voltage conversion capability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the voltage conversion function across multiple secondary windings with different turn ratios rather than using a single transformer with extreme turn ratios. Each secondary winding can be connected in series or parallel to achieve different output voltages, providing flexible voltage conversion capability while keeping individual transformer sections manageable and reducing overall system complexity.
Solution Approach 2:
The system provides dynamic voltage conversion capability by allowing flexible connection configurations of multiple secondary windings (series or parallel) and multiple DC/AC converters. This dynamic reconfigurability enables the system to adapt to different voltage requirements without requiring fixed, complex transformer designs.
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 design achieves miniaturization while maintaining high-voltage and high-current capabilities, reducing power loss and enhancing controllability and reliability by minimizing transformer dimensions and preventing cross-currents.
Implementation Method 1
a multiple transformer 300a having a plurality of primary windings 301 and a plurality of secondary windings 302, in which a magnetic path is shared among the plurality of primary windings 301 and a magnetic path is shared among the plurality of secondary windings 302
Data Source
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AI summary
A power converter (10a) performs DC power conversion between a pair of first DC terminals (20) and a pair of second DC terminals (30). DC nodes of n DC/AC converters (100) are connected in parallel or in series between the first DC terminals (20). A multiple transformer (300a) has n primary windings (301) and n secondary windings (302). An AC node of each DC/AC converter (100) is connected to its corresponding primary winding (301). An AC node of each AC/DC converter (200) is connected to its corresponding secondary winding (302). DC nodes of n AC/DC converters (200) are connected in series or in parallel between the second DC terminals (30). The multiple transformer (300a) is configured such that a magnetic path is shared among the n primary windings (301) and a magnetic path is shared among the n secondary windings (302).