Method and system for single stage battery charging

Patent metadata

Field	Value
Publication number	US-10389166-B1
Application number	US-201715712795-A
Country	US
Kind code	B1
Filing date	Sep 22, 2017
Priority date	Sep 23, 2016
Publication date	Aug 20, 2019
Grant date	Aug 20, 2019

Abstract

Aspects of the present disclosure involve a system and method for providing a boosted voltage using a single stage dual active bridge converter. In one embodiment, the single stage dual active bridge converter is introduced for high voltage charging using phase shift and frequency control. Phase shift and frequency control can be implemented on duty cycled switches and pulse width modulated switches in order to achieve a desired output voltage. In another embodiment, the phase shift and frequency controlled single stage dual active bridge converter is replicated in modular form to provide a single-phase system that provides a voltage for charging a high voltage system. In yet another embodiment, the phase shift and frequency controlled single stage dual active bridge converter is replicated in modular form to provide a three-phase system that provides a voltage for charging a high voltage system.

First claim

What is claimed is:

1. A method for charging a battery comprising:
obtaining an output voltage of a battery, wherein the obtained output voltage is within one of a plurality of predetermined voltage zones, the predetermined voltage zones defined by a first threshold level and a second threshold level;
sensing an instantaneous voltage at an input of a first H-bridge circuit of a single stage charger circuit;
calculating a frequency shift value and a phase shift value from the voltage difference voltage of the output voltage and the sensed instantaneous voltage;
transmitting the frequency shift value and the phase shift value to a modulator, the modulator generating a frequency control signal based on the frequency shift value and a phase shift control signal based on the phase shift value, the frequency control signal and the phase shift control signal corresponding to the one of the plurality of predetermined voltage zones of the obtained output voltage; and
controlling, utilizing the modulator, a plurality of switches in the first H-bridge based on the frequency control signal and the phase shift control signal to provide a charging output power to the battery.

2. The method of claim 1 , wherein the frequency shift value transmitted to the modulator is an output of a frequency control loop circuit.

3. The method of claim 2 , wherein the phase shift value transmitted to the modulator is an output of a phase shift control loop circuit.

4. The method of claim 1 , wherein a first voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages below the first threshold level and wherein the frequency control signal provides a constant frequency control to the first H-bridge circuit and the phase shift control signal provides the phase shift value to the first H-bridge circuit.

5. The method of claim 4 wherein the controlling the plurality of switches in the first H-bridge when the output voltage of the battery is within the first voltage zone provides a constant desired output power of the single stage charger circuit to the battery.

6. The method of claim 1 , wherein a second voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages between the first threshold level and the second threshold level and controlling the plurality of switches in the first H-bridge circuit comprises providing a linearly increasing frequency control that applies the frequency shift value to the first H-bridge circuit.

7. The method of claim 6 wherein the controlling the plurality of switches in the first H-bridge when the output voltage of the battery is within the second voltage zone provides a constant desired output power of the single stage charger circuit to the battery.

8. The method of claim 1 , wherein a third voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages above the second threshold level and wherein the frequency control signal provides a constant frequency control to the first H-bridge circuit at a first minimum operating frequency and the phase shift control signal provides a linearly declining phase shift control that applies the phase shift value to the first H-bridge circuit.

9. The method of claim 3 , wherein an output of the phase shift control loop circuit and an output of the frequency control loop circuit are transmitted to the modulator to control the switches of the first H-bridge circuit.

10. The method of claim 3 , wherein the frequency control loop circuit further comprises a carrier generator module.

11. The method of claim 3 , wherein the frequency shift value and the phase shift value are controlled on the first H-bridge circuit relative to a second H-bridge circuit.

12. A single stage battery charger circuit comprising:
a power factor correction (PFC) converter comprising a first H-bridge circuit comprising a plurality of switches;
a transformer circuit in electrical communication with the PFC converter;
a converter circuit in electrical communication with the transformer circuit, the converter circuit comprising a second H-bridge circuit; and
a control circuit configured to:
obtain an output voltage of a battery, wherein the obtained output voltage is within one of a plurality of predetermined voltage zones, the predetermined voltage zones defined by a first threshold level and a second threshold level;
calculate a frequency shift value and a phase shift value from the voltage difference voltage of the output voltage and a sensed instantaneous voltage at an input of a first H-bridge circuit of a single stage charger circuit;
calculate a frequency shift value and a phase shift value from the voltage difference voltage of the output voltage and the sensed instantaneous voltage at an input of the first H-bridge circuit of the PFC converter, wherein the frequency shift value and the phase shift value are based at least on the one of the plurality of predetermined voltage zones corresponding to the obtained output voltage;
transmit the frequency shift value and the phase shift value to a modulator, the modulator generating a frequency control signal based on the frequency shift value and a phase shift control signal based on the phase shift value, the frequency control signal and the phase shift control signal corresponding to the one of the plurality of predetermined voltage zones of the obtained output voltage; and
control, utilizing the modulator, a plurality of switches in the first H-bridge based on the frequency control signal and the phase shift control signal to provide a charging output power to the battery.

13. The circuit of claim 12 , wherein the control circuit comprises a frequency control loop circuit providing a frequency control for the first H-bridge circuit and a phase shift control loop circuit providing a phase shift control for the first H-bridge circuit.

14. The circuit of claim 13 , wherein a first voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages below the first threshold level and controlling a plurality of switches in the first H-bridge circuit comprises providing a constant frequency control at a first minimum operating frequency and a phase shift control that applies the frequency shift value to the first H-bridge circuit.

15. The circuit of claim 14 wherein the controlling the plurality of switches in the first H-bridge when the output voltage of the battery is within the first voltage zone provides a constant desired output power of the single stage charger circuit to the battery.

16. The circuit of claim 13 , wherein a second voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages between the first threshold level and the second threshold level and controlling a plurality of switches in the first H-bridge circuit comprises a linearly increasing frequency control that applies the frequency shift value to the first H-bridge circuit.

17. The circuit of claim 16 wherein the controlling the plurality of switches in the first H-bridge when the output voltage of the battery is within the second voltage zone provides a constant desired output power of the single stage charger circuit to the battery.

18. The circuit of claim 13 , wherein a third voltage zone of the plurality of predetermined voltage zones comprises obtained output voltages above the second threshold level and controlling the plurality of switches in the first H-bridge circuit comprises a constant frequency control at a first minimum operating frequency that applie

Assignees

• Apple Inc

Inventors

• Sahoo Ashish K
• Mazumdar Poornima
• Sun Nancy Y
• Zahid Zaka Ullah
• Lee Dong Young

Classifications

• H02M7/219

  in a bridge configuration · CPC title

• H02M7/793

  using discharge tubes only · CPC title

• H02J2101/20

  Dispersed power generation using renewable energy sources · CPC title

• H02J7/963

  in response to battery voltage gradient · CPC title

• H02J7/947

  in response to integrated charge or discharge current · CPC title