Switch-Mode DC-DC Transformer with Segmented Windings
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Solution Overview
Problem
High-frequency power supplies for cloud computing and data centers face limitations in power efficiency due to magnetic core losses and increased common mode noise, primarily caused by proximity and eddy current effects in copper wires, as well as higher voltage changes in transformer windings.
Innovation Solution
A switch-mode DC-DC power converter design featuring transformers with winding sets where primary and secondary windings are magnetically coupled with a specific turns ratio and separated by spacers to reduce magnetic coupling between adjacent sets, minimizing common mode noise while maintaining high power efficiency at high switching frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high frequency switching is used to increase power density, then power efficiency is improved, but magnetic core losses and common mode noise increase
Solution Approach 1:
The transformer is divided into multiple winding sets (first, second, third, fourth) with alternating primary and secondary windings. This segmentation allows for reduced magnetic coupling between adjacent winding sets, thereby reducing magnetic core losses while maintaining high frequency operation for improved power density.
Solution Approach 2:
Different winding sets are positioned with varying magnetic coupling characteristics. The local magnetic coupling between adjacent winding sets is reduced through specific positioning, while the overall transformer maintains efficient energy transfer. This local optimization reduces eddy current losses in specific regions without compromising overall performance.
2Productivity
If high frequency switching is used to increase power density, then power efficiency is improved, but common mode noise increases
Solution Approach 1:
The transformer is divided into multiple winding sets (first, second, third, fourth) with alternating primary and secondary windings. This segmentation allows for reduced magnetic coupling between adjacent winding sets, thereby reducing magnetic core losses while maintaining high frequency operation for improved power density.
Solution Approach 2:
Different winding sets are positioned with varying magnetic coupling characteristics. The local magnetic coupling between adjacent winding sets is reduced through specific positioning, while the overall transformer maintains efficient energy transfer. This local optimization reduces eddy current losses in specific regions without compromising overall performance.
3Reliability
If copper wires are used for windings, then electrical conductivity is improved, but proximity and eddy current losses increase at high frequency
Solution Approach 1:
Different winding sets are positioned with varying magnetic coupling characteristics. The local magnetic coupling between adjacent winding sets is reduced through specific positioning, while the overall transformer maintains efficient energy transfer. This local optimization reduces eddy current losses in specific regions without compromising overall performance.
Solution Approach 2:
The transformer windings are arranged in a multi-dimensional configuration with alternating primary and secondary windings positioned in space. This spatial arrangement reduces proximity effects and eddy current losses by increasing the distance between adjacent windings of the same type, while maintaining effective magnetic coupling through the core.
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 effectively reduces common mode noise and maintains high power efficiency by matching voltage changes over time and lowering AC resistance in windings, thereby addressing the limitations of existing technologies.
Implementation Method 1
Each winding set includes a primary winding and a secondary winding magnetically coupled with one another
Implementation Method 2
at least one spacer positioned to separate an adjacent pair of the plurality of winding sets
Data Source
AI summary
A switch-mode DC-DC power converter includes one or more input terminals and output terminals, and a transformer coupled between the input and output terminals. The transformer includes a plurality of winding sets. Each winding set includes a primary winding and a secondary winding magnetically coupled with one another. The primary winding and the secondary winding include the same number of turns. The primary windings of the plurality of winding sets are connected in series and the secondary windings of the plurality of winding sets are connected in parallel. The power converter also includes at least one spacer positioned to separate an adjacent pair of the plurality of winding sets. A magnetic coupling between the adjacent pair of the plurality of winding sets is less than the magnetic coupling between the primary winding and the secondary winding within each winding set.