Unidirectional Multi-Level DC-DC Converter with Integrated Transformer
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Solution Overview
Problem
Conventional multi-level DC-DC converters require sophisticated control and result in high manufacturing costs and dimensions due to the use of dual half-bridge inverters and high-frequency transformers, leading to inefficiencies and increased ripple in output voltages and currents.
Innovation Solution
A unidirectional isolated multi-level DC-DC converter is designed with a single inverter, a 3-winding high-frequency transformer, and a selection circuit that generates low-harmonic pulse voltages, reducing the capacity of the filter circuit and simplifying the structure, thereby minimizing dimensions and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional multi-level DC-DC converter uses dual half-bridge inverters and high-frequency transformers, then the converter can achieve multi-level voltage output, but the device dimensions and manufacturing cost increase
Solution Approach 1:
The patent combines two separate high-frequency transformers into a single integrated transformer with primary and secondary windings, reducing the overall device volume while maintaining the multi-level voltage output capability through coordinated switching of power semiconductors
Solution Approach 2:
The single integrated transformer performs multiple functions: voltage transformation, isolation, and enabling multi-level output through different winding combinations, replacing what would traditionally require separate transformer units
2Adaptability or versatility
If a conventional multi-level DC-DC converter uses dual half-bridge inverters, then the converter can generate three levels of voltages, but the control complexity increases
Solution Approach 1:
The patent merges two half-bridge inverter circuits into a single unified inverter structure with coordinated power semiconductor switching, simplifying the control architecture while maintaining three-level voltage generation capability through integrated control logic
3Power
If a conventional multi-level DC-DC converter uses four capacitors with different capacitances, then the converter can achieve voltage multiplication, but the voltage imbalance and control difficulty increase
Solution Approach 1:
The patent applies different capacitance values to different capacitor positions within the circuit (C1=C2=C3 vs. C4=C5=C6) to optimize voltage distribution and balance, achieving voltage multiplication while reducing voltage imbalance through localized capacitance optimization rather than using four different capacitance values
4Power
If a conventional multi-level DC-DC converter uses two high-frequency transformers with iron cores, then the converter can achieve voltage transformation, but the manufacturing cost and dimensions increase
Solution Approach 1:
The patent combines two separate high-frequency transformers into a single integrated transformer unit, reducing the quantity of iron cores and magnetic materials required, thereby lowering manufacturing cost and dimensions while maintaining voltage transformation capability through optimized winding configurations
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 solution effectively reduces the dimensions and manufacturing costs while enhancing operational efficiency by minimizing ripple in output voltages and currents, achieving a more compact and cost-effective design.
Implementation Method 1
a 3-winding high-frequency transformer including a primary side and a secondary side, with the primary side having a first winding, with the first winding connecting with the AC output end of the inverter, with the secondary side having a second winding and a third winding
Data Source
AI summary
A multi-level DC-DC converter device includes an inverter, a 3-winding high-frequency transformer, a first full-bridge rectifier, a second full-bridge rectifier, a selective circuit and a filter circuit. A first winding at a primary side of the high-frequency transformer connects with the inverter while a second winding and a third winding of at a secondary side of the high-frequency transformer connect with the first full-bridge rectifier and the second full-bridge rectifier. The selective circuit connects with DC output ports of the first full-bridge rectifier and the second full-bridge rectifier, thereby operationally selecting two serially-connected full-bridge rectifiers or single full-bridge rectifier to output two voltage levels performed as a multi-level output voltage. The filter circuit connects between the selective circuit and a load for filtering harmonics and outputting a DC voltage.