CN-122026687-A - High-power conversion device

Abstract

The invention provides a circuit topology and a control mode aiming at high-power application of high voltage dropping ratio of input voltage to output voltage, wherein the circuit topology has low switching loss and high conversion efficiency in the occasion of high-frequency switching of a power switch. The invention also provides a power conversion device applying the circuit topology, provides device layout setting of the power conversion device and a winding mode of a transformer, further reduces the volume of the power conversion device under the condition of meeting high power output, and improves the steady-state performance and the dynamic performance of the conversion device.

Inventors

• JIN DA
• XIONG YAHONG

Assignees

• 上海沛塬电子有限公司

Dates

Publication Date

20260512

Application Date

20251111

Priority Date

20241111

Claims (20)

1. 1. The high-power conversion device is characterized by comprising a high-voltage unit, a low-voltage unit, an input capacitor, an output capacitor, an input positive end, an input negative end, an output positive end and an output negative end, wherein the high-voltage unit comprises a first high-voltage unit and a second high-voltage unit, the low-voltage unit comprises a first low-voltage unit and a second low-voltage unit, and the input capacitor comprises a first input capacitor and a second input capacitor; Each high-voltage unit comprises a switch and a high-voltage winding, the two high-voltage windings are respectively a first high-voltage winding and a second high-voltage winding, each low-voltage unit comprises a switch and a low-voltage winding, the two low-voltage windings are respectively a first low-voltage winding and a second low-voltage winding, and the two high-voltage windings and the two low-voltage windings are coupled through the same magnetic core assembly; the first input capacitor and the first high-voltage unit are connected in parallel and then connected between the input positive end and the input middle point, and the second input capacitor and the second high-voltage unit are connected in parallel and then connected between the input middle point and the input negative end; The first low-voltage unit and the second low-voltage unit are electrically connected in parallel between an output positive end and an output negative end, and the output capacitor is connected between the output positive end and the output negative end in a bridging way; The power conversion device further comprises a substrate, a plurality of hole grooves, a magnetic core assembly, a magnetic cover and a magnetic cover, wherein the substrate comprises an upper surface and a lower surface which are opposite, the hole grooves penetrate through the upper surface and the lower surface, the magnetic core assembly comprises a magnetic column, a side column, an upper magnetic cover and a lower magnetic cover, the magnetic column and the side column penetrate through the hole grooves respectively, and the upper magnetic cover and the lower magnetic cover respectively fasten the substrate from the upper surface and the lower surface; The switch in the high voltage unit is disposed adjacent a first side of the magnetic core assembly, the switch in the first low voltage unit is disposed adjacent a second side of the magnetic core assembly, and the switch in the second low voltage unit is disposed adjacent a fourth side of the magnetic core assembly.
2. 2. The power conversion device of claim 1, wherein both ends of each of the high voltage windings are disposed adjacent a first side of the magnetic core assembly, both ends of the switch and the low voltage winding in the first low voltage unit are disposed adjacent a second side of the magnetic core assembly, and both ends of the switch and the low voltage winding in the second low voltage unit are disposed adjacent a fourth side of the magnetic core assembly.
3. 3. The power conversion device of claim 1, wherein the magnetic posts comprise a first magnetic post, a second magnetic post, a third magnetic post, and a fourth magnetic post, the side posts comprising a first side post and a second side post, the first side post being disposed adjacent to a first side of the magnetic core assembly, the second side post being disposed adjacent to a third side of the magnetic core assembly, four of the magnetic posts being disposed in a 2x2 array between the first side post and the second side post, the first magnetic post and the third magnetic post being disposed adjacent to the first side post, the second magnetic post and the fourth magnetic post being disposed adjacent to a second side of the magnetic core assembly, the first magnetic post and the second magnetic post being disposed adjacent to a fourth side of the magnetic core assembly.
4. 4. The power conversion device according to claim 3, wherein a first end of the first low-voltage winding is disposed between the first magnetic pole and the second magnetic pole, a second end of the first low-voltage winding is disposed between the first side pole and the first magnetic pole and between the second side pole and the second magnetic pole, respectively, the first low-voltage winding is wound around the first magnetic pole and the second magnetic pole in opposite directions from the first end to the second end, respectively, a first end of the second low-voltage winding is disposed between the third magnetic pole and the fourth magnetic pole, a second end of the second low-voltage winding is disposed between the first side pole and the third magnetic pole and between the second side pole and the fourth magnetic pole, respectively, the second low-voltage winding is wound around the third magnetic pole and the fourth magnetic pole in opposite directions from the first end to the second end, respectively, and the first low-voltage winding is wound around the third magnetic pole in opposite directions from the first end to the second end.
5. 5. The power conversion device of claim 4, wherein the substrate comprises a plurality of wiring layers, the first high voltage winding is wound around the first magnetic post and the second magnetic post in opposite directions from the first end to the second end, respectively, the second high voltage winding is wound around the third magnetic post and the fourth magnetic post in opposite directions from the first end to the second end, respectively, at least two turns, and the winding direction of the first high voltage winding on the first magnetic post and the winding direction of the second high voltage winding on the third magnetic post are opposite.
6. 6. The power conversion device according to claim 5, wherein the high voltage winding is wound in at least two layers, the first high voltage winding is wound from the first end to the second end in a first layer, clockwise around the first magnetic pillar, then around the second magnetic pillar in a clockwise direction, then around the second magnetic pillar in a counterclockwise direction, then through the second via hole to the second layer, on the second layer, first around the second magnetic pillar in a counterclockwise direction, then around the first magnetic pillar in a clockwise direction, then around the first layer in a first direction Kong Huidao, then around the first magnetic pillar in a clockwise direction, then around the first magnetic pillar in a first layer in a clockwise direction, then around the first magnetic pillar in a clockwise direction, then around the second end in a first direction, the second high voltage winding is wound from the first end to the second end in a first layer in a counterclockwise direction, then around the third magnetic pillar in a counterclockwise direction, then around the third via hole to the second layer in a counterclockwise direction, then around the fourth magnetic pillar in a clockwise direction, through the fourth Kong Huidao, then around the first layer in a clockwise direction, then around the first magnetic pillar in a counterclockwise direction, and then around the first magnetic pillar in a second layer.
7. 7. The power conversion device according to claim 5, wherein two of the high-voltage windings are provided on two wiring layers, and both ends of the two high-voltage windings are provided on different wiring layers.
8. 8. The power conversion device of claim 2, wherein the switches in each of the high voltage units comprise a first upper switch, a second upper switch, a first middle switch, a second middle switch, and a resonant capacitor, wherein each of the high voltage units further comprises a first resonant capacitor and a second resonant capacitor, wherein in the first high voltage unit the first upper switch and the first middle switch are electrically connected in series at a first upper node and are connected in series across an input positive terminal and an input midpoint, wherein the second upper switch and the second middle switch are electrically connected in series at a second upper node and are connected in series across an input positive terminal and an input midpoint, wherein the first resonant capacitor and a first end of a first high voltage winding are connected in series and are connected in series across a first upper node and a second upper node, wherein the second end of the first high voltage winding is electrically connected to a second upper node, wherein in the second high voltage unit the first upper switch and the first middle switch are connected in series at a third upper node and are connected in series across a negative terminal and an input midpoint, wherein the second upper switch and are connected in series across a fourth upper node.
9. 9. The power conversion device according to claim 8, wherein the switches in each of the low voltage units comprise a first lower switch, a second lower switch, a third lower switch, and a fourth lower switch, wherein in the first low voltage unit the first lower switch and the second lower switch are electrically connected in series between the output positive terminal and the output negative terminal and are connected in series between the second lower node and are connected in series between the output positive terminal and the output negative terminal, wherein a first end of the first low voltage winding is electrically connected to the first lower node, wherein a second end of the first low voltage winding is electrically connected to the second lower node, wherein in the second low voltage unit the first lower switch and the second lower switch are connected in series between the output positive terminal and the output negative terminal and are connected in series between the fourth lower node and are connected in series between the output positive terminal and the output negative terminal, wherein the second end of the first low voltage winding is electrically connected to the second lower node, and the second end of the first low voltage winding is connected to the second lower node.
10. 10. The power conversion device of claim 9, further comprising a first control signal, a second control signal, a third control signal, and a fourth control signal, wherein the first control signal and the second control signal are each 50% duty cycle, 180 degrees out of phase, and wherein the third control signal is complementary to the first control signal and the fourth control signal is complementary to the second control signal.
11. 11. The power conversion device according to claim 10, wherein the first control signal is used for controlling on and off of a first upper switch and a second middle switch in the two high voltage units, the second control signal is used for controlling on and off of a second upper switch and a first middle switch in the two high voltage units, the third control signal is used for controlling on and off of a second lower switch and a third lower switch in the two low voltage units, and the fourth control signal is used for controlling on and off of a first lower switch and a fourth lower switch in the two low voltage units.
12. 12. The power conversion device according to claim 10, wherein the second end of each of the high voltage windings and the second end of each of the low voltage windings are synonymous ends with each other.
13. 13. The power conversion device of claim 8, wherein the first resonant capacitor is disposed between the switch in the first high voltage unit and the first side of the magnetic core assembly and the second resonant capacitor is disposed between the switch in the second high voltage unit and the first side of the magnetic core assembly.
14. 14. The power conversion device of claim 1, wherein the first high voltage unit is connected across the input positive terminal and the input midpoint, the second high voltage unit is connected across the input midpoint and the input negative terminal, the first input capacitance is disposed adjacent to a switch in the first high voltage unit, and the second input capacitance is disposed adjacent to a switch in the second high voltage unit.
15. 15. The power conversion device according to claim 1, wherein the switches in the two high voltage units are disposed on an upper surface of the substrate, the first input capacitance and the second input capacitance are disposed on a lower surface of the substrate, and wherein the projection of the first input capacitance and the projection of the switch in the first high voltage unit on the same horizontal plane are at least partially overlapped, and the projection of the second input capacitance and the projection of the switch in the second high voltage unit on the same horizontal plane are at least partially overlapped.
16. 16. The power conversion device according to claim 1, wherein a part of the switches in the two high-voltage units is provided on an upper surface of the substrate, and the other part of the switches in the two high-voltage units is provided on a lower surface of the substrate.
17. 17. The power conversion device according to claim 1, wherein the switches in the two low voltage units are arranged on the upper surface of the substrate, the output capacitor is arranged on the lower surface of the substrate, and the output capacitor is at least partially overlapped with the projection of the switches in each low voltage unit on the same horizontal plane.
18. 18. The power conversion device according to claim 1, wherein a part of the switches in the two low-voltage units are provided on an upper surface of the substrate, and the other part of the switches in the two low-voltage units are provided on a lower surface of the substrate.
19. 19. The power conversion device of claim 1, further comprising an input terminal disposed adjacent to a switch in the high voltage unit and an output terminal disposed adjacent to a third side of the magnetic core assembly.
20. 20. The power conversion device of claim 3, wherein a first gap exists between the first leg and the second side of the magnetic core assembly, the switch in the first high voltage unit is disposed adjacent to the first gap, two ends of the first high voltage winding are electrically connected with the switch in the first high voltage unit through the first gap, a second gap exists between the first leg and the fourth side of the magnetic core assembly, the switch in the second high voltage unit is disposed adjacent to the second gap, and two ends of the second high voltage winding are electrically connected with the switch in the second high voltage unit through the second gap.

Description

High-power conversion device Technical Field The invention belongs to the technical field of high-frequency power supplies, and particularly relates to a power conversion device. With the development of artificial intelligence, the power requirements of intelligent data processing chips such as GPU/CPU/NPU (collectively xPU) are higher and higher, so that the power of a server is greatly increased, and the input voltage of the server is gradually changed from 12V to 48V, so that the voltage reduction ratio of the input voltage to the output voltage is higher and higher. The power required for xPU is also higher and higher, and in order to obtain a high input-output voltage gain ratio and high power applications, a circuit architecture and a conversion device with high conversion efficiency are needed. The invention aims at the solution of the power conversion device with high input-output voltage gain ratio, and reduces the input voltage of each high-voltage full-bridge unit by adopting the serial connection of the input ends of the high-voltage full-bridge units, thereby reducing the switching loss of the power switching devices in each high-voltage full-bridge unit under high-frequency switching, improving the conversion efficiency of the whole power conversion device, reducing the jump voltage difference of a transformer by the serial connection of the high-voltage sides, and obtaining better EMI characteristics. Disclosure of Invention In view of the above, it is an object of the present invention to provide a circuit topology and a control timing, which are suitable for applications with high voltage step-down ratio of input voltage to output voltage, and the circuit topology has low switching loss and high conversion efficiency in high-power switch high-frequency switching. The invention also provides a power conversion device applying the circuit topology, provides device layout setting of the power conversion device and a winding mode of a transformer, reduces the volume of the power conversion device, and improves the steady-state performance and the dynamic performance of the conversion device. The invention provides a high-power conversion device which comprises a high-voltage unit, a low-voltage unit, an input capacitor, an output capacitor, an input positive end, an input negative end, an output positive end and an output negative end, wherein the high-voltage unit comprises a first high-voltage unit and a second high-voltage unit, the low-voltage unit comprises a first low-voltage unit and a second low-voltage unit, and the input capacitor comprises a first input capacitor and a second input capacitor; Each high-voltage unit comprises a switch and a high-voltage winding, the two high-voltage windings are respectively a first high-voltage winding and a second high-voltage winding, each low-voltage unit comprises a switch and a low-voltage winding, the two low-voltage windings are respectively a first low-voltage winding and a second low-voltage winding, and the two high-voltage windings and the two low-voltage windings are coupled through the same magnetic core assembly; the first input capacitor and the first high-voltage unit are connected in parallel and then connected between the input positive end and the input middle point, and the second input capacitor and the second high-voltage unit are connected in parallel and then connected between the input middle point and the input negative end; The first low-voltage unit and the second low-voltage unit are electrically connected in parallel between an output positive end and an output negative end, and the output capacitor is connected between the output positive end and the output negative end in a bridging way; The power conversion device further comprises a substrate, a plurality of hole grooves, a magnetic core assembly, a magnetic cover and a magnetic cover, wherein the substrate comprises an upper surface and a lower surface which are opposite, the hole grooves penetrate through the upper surface and the lower surface, the magnetic core assembly comprises a magnetic column, a side column, an upper magnetic cover and a lower magnetic cover, the magnetic column and the side column penetrate through the hole grooves respectively, and the upper magnetic cover and the lower magnetic cover respectively fasten the substrate from the upper surface and the lower surface; The switch in the high voltage unit is disposed adjacent a first side of the magnetic core assembly, the switch in the first low voltage unit is disposed adjacent a second side of the magnetic core assembly, and the switch in the second low voltage unit is disposed adjacent a fourth side of the magnetic core assembly. Preferably, both ends of each of the high voltage windings are disposed adjacent to a first side of the magnetic core assembly, both ends of the switch and the low voltage winding in the first low voltage unit are disposed adjacent to a second side of the magnetic co