Single-Primary-Coil DC-DC Converter for Multi-Battery Isolation
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Solution Overview
Problem
Conventional DC-DC converters require multiple primary coils for each battery source, leading to increased size, cost, and reduced efficiency due to thicker wires and complex transformer designs.
Innovation Solution
A DC-DC converter design with a single primary coil connected to multiple battery sources, utilizing a controller to manage switching operations among input switch sets to ensure only one battery source is active at a time, reducing the need for multiple primary coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple primary coils are allocated to each battery source, then safety and insulation are improved, but the size, cost, and complexity of the transformer and converter increase
Solution Approach 1:
The patent divides the battery sources into separate groups, with each group having its own dedicated primary coil and switch set. This segmentation allows for isolated control and insulation of each battery source while using a single shared transformer core, thereby maintaining safety without requiring multiple complete transformer units. The transformer is segmented in function rather than physically separated into multiple complete units.
Solution Approach 2:
The patent creates a universal transformer structure that can handle multiple battery sources through a single primary coil that accepts input from any connected battery source. The transformer serves multiple functions by being able to convert power from different battery sources (e.g., traction battery, auxiliary battery) through the same magnetic core and secondary coils, eliminating the need for dedicated transformers for each battery type.
2Reliability
If multiple primary coils are allocated to each battery source, then insulation between input sources is improved, but the size and cost of the converter increase
Solution Approach 1:
The converter is segmented into multiple independent input channels, each with its own switch set and control circuitry, but sharing a common transformer core and primary coil structure. This allows insulation to be implemented at the switching level rather than requiring physically separate transformer units for each battery source, reducing overall converter size while maintaining safety.
Solution Approach 2:
The patent merges multiple battery input channels into a single shared transformer primary coil and core structure. By combining the magnetic paths and structural components while maintaining separate switching control for each battery source, the design achieves insulation between inputs without duplicating the entire transformer assembly for each battery, thereby reducing converter size and cost.
3Power
If the capacity of the battery and DC-DC converter increase, then power conversion capability is improved, but the transformer structure becomes a negative factor in efficiency and size
Solution Approach 1:
The transformer is designed as a universal high-capacity unit that can handle power conversion from multiple different battery sources simultaneously or sequentially. The single primary coil and shared magnetic core are dimensioned to accommodate the maximum power requirements of any connected battery source, eliminating the need for multiple smaller transformers and improving overall power conversion efficiency while managing size.
Solution Approach 2:
The patent employs parameter optimization in the transformer design, including adjusting the magnetic core material properties, winding configurations, and switching frequencies to maximize power conversion efficiency at high capacities. By changing these parameters, the transformer can handle increased power levels without proportionally increasing in size, thus improving the power-to-size ratio.
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 reduces the size and cost of the converter while maintaining safety through insulation, and enhances efficiency by simplifying the transformer structure.
Implementation Method 1
a primary coil connected to a plurality of battery sources and a secondary coil connected to a load
Data Source
AI summary
A DC-DC converter, located between a plurality of batteries and a power conversion system, comprises a primary coil connected to a plurality of battery sources and a secondary coil connected to a load through an output switch set, wherein the primary coil may be connected to the plurality of battery sources through a plurality of input switch sets corresponding to the plurality of battery sources.