Synchronous Rectifier Integration in High-Current Transformers
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Solution Overview
Problem
Resistance welding devices with high-current transformers and separate rectifiers suffer from high losses and low efficiency due to long wiring lengths, leading to significant energy wastage and high connected loads, resulting in poor energy balance and increased costs.
Innovation Solution
Integration of switching elements, control circuits, and supply circuits on a circuit board within the high-current transformer, eliminating the need for external wiring and allowing for direct connection to the transformer, with a compact design that reduces line lengths and inductances, and includes a data communication circuit for wireless data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate construction of high-current transformer and rectifier is used, then device complexity is reduced and ease of manufacture is improved, but line losses increase and efficiency deteriorates
Solution Approach 1:
The patent merges the rectifier circuit with the high-current transformer by integrating switching elements, control circuits, and supply circuits directly onto the transformer's circuit board. This consolidation eliminates separate wiring connections between independent transformer and rectifier units, thereby reducing line losses while maintaining manufacturing feasibility through modular integration
2Ease of repair
If switching elements are separately connected to transformer, then ease of repair is improved and device complexity is reduced, but wiring length increases and efficiency deteriorates
Solution Approach 1:
The switching elements are integrated directly onto the transformer's circuit board, eliminating external wiring connections. This integration reduces line losses and inductive effects while maintaining repairability through standardized circuit board modules that can be replaced or serviced without affecting the entire transformer assembly
Solution Approach 2:
The patent transitions from three-dimensional external wiring connections to a two-dimensional circuit board layout, where switching elements are mounted on the same plane as the transformer windings. This dimensional change minimizes connection length and inductance while preserving access for repair and maintenance activities
3Device complexity
If conventional rectifier construction is used, then device complexity is reduced, but connected load increases and operational costs deteriorate
Solution Approach 1:
The integration of control circuits and supply circuits directly onto the transformer circuit board enables optimized switching sequences and reduced idle losses. This merging eliminates redundant wiring and control infrastructure, reducing the connected load requirement while maintaining manageable device complexity through integrated control architecture
Solution Approach 2:
The patent changes the operational parameters by implementing active synchronous rectification with controlled switching elements instead of passive diode rectification. This parameter change enables the system to operate more efficiently, reducing the connected load requirement while the integrated circuit board design keeps device complexity at acceptable levels
Data Source
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AI summary
The invention relates to a synchronous rectifier (16) for integration into a power source (10) in order to provide a direct current, in particular in a cube- or square-shaped unit of a heavy-current transformer (12), comprising circuit elements (24), an actuation circuit (17) for actuating the circuit elements (24) and a supply circuit (48), wherein a printed circuit board (35) with conductor tracks and connection surfaces is provided for receiving electronic components. In order to reduce losses and improve the efficiency, the circuit elements (24), the actuation circuit (17) and the supply circuit (48) are arranged on the printed circuit board (35) for the autonomous operation thereof, wherein several openings (37), which are arranged in parallel and in series, are provided on the printed circuit board (35) for receiving protrusions (36) of a contact plate (29), and wherein the circuit elements (24) are arranged and connected or soldered above said openings (37) and can be contacted with the protrusions (36) of the contact plate (29).