Single Tapped Transformer Power Converter for Dual Voltage Ranges

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Solution Overview

Problem

Existing power converter systems require two separate transformers and controllers to handle multiple ranges of input voltages, increasing cost and space requirements, especially in small and portable devices.

Innovation Solution

A power converter system utilizing a single tapped transformer with two control modules and switching devices, one connected at the tap terminal and the other at the end of the primary winding, to accommodate both high and low voltage ranges by selectively activating the appropriate control module based on the input voltage magnitude.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If two separate power systems with their own transformers are provided for multiple input voltage ranges, then the power converter can accommodate both high and low voltage ranges, but the cost and space requirements increase

Engineering Contradiction:

Improveinput voltage range accommodationVSAvoidspace requirement

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The patent combines two separate power conversion systems into a single integrated system by sharing a common transformer. The transformer has a primary winding with a tap point that allows two different control modules to share the same magnetic core and transformer structure, thereby reducing the overall space requirement while maintaining compatibility with multiple input voltage ranges

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single transformer is designed to serve multiple functions by accommodating both high voltage and low voltage input ranges through its tapped primary winding. The same transformer core and magnetic path are utilized for both voltage ranges, making the transformer a universal component that performs power conversion for different input conditions without requiring separate dedicated transformers

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

Engineering Contradiction:

Improveinput voltage range accommodationVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges two separate power conversion paths into one shared transformer structure. By having both control modules interface with the same transformer through the tapped primary winding, the bill of materials is reduced (fewer transformers, fewer magnetic cores, fewer associated components), directly lowering manufacturing costs while maintaining the capability to handle multiple input voltage ranges

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transformer is designed as a universal component that can handle both high and low voltage inputs through its multi-tap primary winding configuration. This universal design eliminates the need to manufacture and stock separate transformers for different voltage ranges, reducing production complexity and cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Area of stationary object

If a single tapped transformer is used for multiple input voltage ranges, then the space and cost are reduced, but the device complexity increases due to multiple control modules and switching devices

Engineering Contradiction:

Improvespace requirementVSAvoidcontrol structure

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The control functionality is segmented into separate modular control modules, each optimized for specific input voltage ranges. Each control module independently manages its portion of the voltage conversion task, which simplifies the control logic within each module while allowing the system as a whole to handle multiple voltage ranges through the segmented, modular architecture

Inventive Principle:

Principle #1Segmentation

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 reduces the size and cost of power converter systems while maintaining efficient voltage regulation across different input voltage ranges, making it suitable for consumer electronics.

Implementation Method 1

A transformer, coupled to the input terminal, has a primary winding and a secondary winding

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

A first switching device, coupled at an end terminal of the primary winding, is operable to be turned on and off to cause current to flow through the primary winding

Methodology Applied

Scientific EffectElectrical switching:

Data Source

PatentUS7729135B1Power converter using a single tapped transformer for multiple ranges of input voltage

Publication Date: 2010.06.01 SEMICON COMPONENTS IND LLC

AI summary

In one embodiment, a power converter system includes an input terminal for an input voltage. A transformer, coupled to the input terminal, has a primary winding and a secondary winding. An output terminal is coupled to the secondary winding. Power is delivered to a load of the power converter system at the output terminal. A first control module, coupled through a relay to a tap terminal to the primary winding of the transformer, operates the power converter system if a magnitude of the input voltage is within a low voltage range. A second control module, coupled at an end terminal of the primary winding of the transformer, operates the power converter system if a magnitude of the input voltage is within a high voltage range.