Power Converter Transformer Winding Selection Control
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Solution Overview
Problem
Power converters require large bulk capacitors due to high capacitance and voltage rating needs, which occupy significant space and are inefficiently reduced by adding conversion stages like boost converters, leading to increased complexity and power loss.
Innovation Solution
A power converter design that includes a rectifier, a bulk capacitor, a transformer, and switches, where a controller determines whether to power the transformer from a rectified voltage node or a bulk capacitor based on sensed voltages, allowing for reduced capacitance and voltage rating of the bulk capacitor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large bulk capacitor is used to meet minimum voltage requirements, then the power converter can operate reliably, but the device occupies significant space and increases in size
Solution Approach 1:
The patent implements dynamic switching between two power supply paths: a first path using a bulk capacitor for stable voltage supply, and a second path using a rectified voltage node for supplemental power. The controller dynamically selects or combines these paths based on real-time voltage conditions, allowing the system to maintain reliable operation with a smaller bulk capacitor while meeting minimum voltage requirements during both line-powered and battery-powered modes.
2Quantity of substance
If a boost converter is added to reduce bulk capacitor size, then the capacitance requirement is reduced, but the device complexity increases
Solution Approach 1:
The patent makes the bulk capacitor serve multiple functions: it acts as the primary energy storage element for voltage regulation during line-powered operation, and simultaneously serves as a charge reservoir that can be discharged during battery-powered operation. This multi-functionality eliminates the need for separate conversion stages like boost converters, reducing device complexity while maintaining the ability to operate with reduced bulk capacitor capacitance.
Solution Approach 2:
The system uses the existing bulk capacitor and rectifier infrastructure to serve dual purposes: during AC power operation, the bulk capacitor is charged from the rectified voltage; during battery operation, the stored energy in the bulk capacitor is discharged to maintain voltage requirements. This self-service approach eliminates the need for additional active conversion stages, reducing complexity while achieving capacitance reduction.
3Volume of moving object
If a boost converter is added to pre-regulate input voltage, then the bulk capacitor size can be reduced, but power loss increases
Solution Approach 1:
The patent performs preliminary charging of the bulk capacitor during line-powered operation, storing energy in advance for later use during battery-powered operation. This preliminary action eliminates the need for continuous active regulation during battery operation, avoiding the power losses associated with boost converter operation while still enabling bulk capacitor size reduction through the dual-power-path architecture.
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 capacitance of the bulk capacitor by 33% while maintaining minimum voltage requirements, improving efficiency and reducing the overall size of the power converter.
Implementation Method 1
The rectifier is configured to input alternating current (AC) power from an input power source and to supply power to a rectified voltage node
Implementation Method 2
The bulk capacitor is supplied power from the input power source and has a storage voltage
Implementation Method 3
The DC/DC voltage converter includes a transformer comprised of primary and secondary windings
Data Source
AI summary
Circuits and methods are provided for supplying power to a transformer of a switching DC/DC voltage converter within a power converter. The power converter includes separate nodes that can potentially supply such power. A first of these nodes is coupled, typically directly and with no energy-storing bulk capacitor, to a rectifier that supplies rectified power from an alternating current power source. A second node is also supplied power from the rectifier, but is coupled to a bulk capacitor that can store and supply energy as needed. The techniques disclosed herein use the first node to supply power to the transformer when feasible, and use the second node, and its associated bulk capacitor, to supply power otherwise. In so doing, the energy storage requirements of the bulk capacitor may be reduced, meaning that the capacitance and associated size of the bulk capacitor may be reduced relative to other power converter circuits.