Multi-phase-shift control of a power converter

Patent metadata

Field	Value
Publication number	US-11277072-B2
Application number	US-201816645030-A
Country	US
Kind code	B2
Filing date	Sep 28, 2018
Priority date	Sep 29, 2017
Publication date	Mar 15, 2022
Grant date	Mar 15, 2022

Abstract

Multi-phase-shift control of a power converter is provided. The power converter includes a dual-active-bridge (DAB) converter having a transformer, a first H-bridge coupled to the primary winding of the transformer, and a second H-bridge coupled to the secondary winding of the transformer. The DAB converter is operable to generate two-level and three-level voltage waveforms on the primary winding and on the secondary winding to yield a system which ensures zero-voltage switching and unity power factor over a wide range of input and output voltage levels and power throughputs. In a multi-phase shift (MPS) mode of operation, the DAB converter changes from a two-level voltage in at least one of the windings to a three-level voltage in both windings in response to the instantaneous load being below a predetermined level, resulting in more efficient performance of the DAB converter in light load conditions.

First claim

The invention claimed is:

1. A system comprising:
a dual-active-bridge (DAB) converter having a transformer, a first H-bridge coupled to a primary winding of the transformer and controlled by first control signals, and a second H-bridge coupled to a secondary winding of the transformer and controlled by second control signals;
a controller to provide the first control signals to the first H-bridge for a two-level voltage waveform or a three-level voltage waveform in the primary winding, the controller being further adapted to provide the second control signals to the second H-bridge for a two-level voltage waveform or a three-level voltage waveform in the secondary winding; and
a load coupled to the second H-bridge of the DAB converter and having a power consumption, wherein, in a dual-phase-shift (DPS) mode of operation, the controller causes a two-level voltage waveform in at least one of the primary winding and the secondary winding, and wherein, in a triple-phase-shift (TPS) mode of operation, the controller causes a three-level voltage waveform in each of the primary winding and the secondary winding,
wherein the controller is operable to cause a transition from the TPS mode of operation to the DPS mode of operation in response to an expected power output of the DAB converter in the TPS mode of operation being equal to an expected power output of the DAB converter in the DPS mode of operation in combination with a detected increase in the power consumption of the load.

2. The system of claim 1 wherein the load includes a rechargeable vehicle battery.

3. The system of claim 1 wherein the controller is adapted to calculate the expected power output of the DAB converter for determining when to transition from the DPS mode of operation to the TPS mode of operation.

4. The system of claim 3 wherein the controller is operable to transition from the DPS mode of operation to the TPS mode of operation when the expected power output of the DAB converter is substantially equal for both modes of operation and the power consumption of the load is decreasing.

5. The system of claim 1 wherein the controller is operable to increase the power output of the DAB converter by lowering a switching frequency of the DAB converter during the DPS mode of operation.

6. The system of claim 1 wherein the DAB converter is coupled to a rectified AC grid voltage.

7. The system of claim 1 further including an inverter adapted to convert an AC grid voltage into a DC voltage for the DAB converter.

8. A method for controlling a dual-active-bridge (DAB) converter having a transformer, a first H-bridge coupled to a primary winding of the transformer, and a second H-bridge coupled to a secondary winding of the transformer, the method comprising:
providing first control signals to the first H-bridge to selectively cause a two-level voltage waveform or a three-level voltage waveform in the primary winding of the transformer;
providing second control signals to the second H-bridge to selectively cause a two-level voltage waveform or a three-level voltage waveform in the secondary winding of the transformer;
wherein, in a dual-phase-shift (DPS) mode of operation, a controller causes a two-level voltage waveform in the primary winding or the secondary winding, wherein, in a triple-phase-shift (TPS) mode of operation, the controller causes a three-level voltage waveform in the primary winding and in the secondary winding, and wherein, at a TPS/DPS equal-power-point, the controller determines that a power output in the TPS mode of operation is equal to a power output in the DPS mode of operation;
in response to a load coupled to the second H-bridge having a high power consumption that is increasing and equal to the TPS/DPS equal-power-point, generating a two-level voltage in at least one of the primary winding and the secondary winding; and
in response to the load transitioning to a low power consumption that is decreasing and equal to the TPS/DPS equal-power-point, generating a three-level voltage waveform in the primary winding and the secondary winding.

9. The method of claim 8 wherein the load includes a rechargeable vehicle battery.

10. The method of claim 8 wherein transitioning from a high power consumption to a low power consumption is determined relative to a predetermined threshold value.

11. The method of claim 8 wherein the primary winding includes a two-level voltage waveform and the secondary winding includes a three-level voltage waveform during high power consumption.

12. The method of claim 8 wherein the primary winding includes a three-level voltage waveform and the secondary winding includes a two-level voltage waveform during high power consumption.

13. The method of claim 8 wherein the primary winding includes a two-level voltage waveform and the secondary winding includes a two-level voltage waveform during high power consumption.

14. The method of claim 8 further including generating a two-level voltage waveform in the primary winding in response to the load returning to the high power consumption.

15. The method of claim 8 further including generating a two-level voltage waveform in the secondary winding in response to the load returning to the high power consumption.

16. The method of claim 8 further including generating a two-level voltage waveform in the first and secondary windings in response to the load returning to the high power consumption.

17. A system comprising:
a dual-active-bridge (DAB) converter having an input H-bridge controlled by first control signals and an output H-bridge controlled by second control signals, wherein an output of the input H-bridge is coupled to an input of the output H-bridge through at least one inductor;
a controller to provide the first control signals to the input H-bridge for causing a two-level voltage waveform or a three-level voltage waveform at the output of the input H-bridge, the controller being further adapted to provide the second control signals to the output H-bridge for causing a two-level voltage waveform or a three-level voltage waveform at the input of the output H-bridge; and
a load coupled to the output H-bridge of the DAB converter and having a power consumption, wherein, in a dual-phase-shift (DPS) mode of operation, the controller causes a two-level voltage waveform in at least one of the output of the input H-bridge and the input of the output H-bridge, and wherein, in a triple-phase-shift (TPS) mode of operation, the controller causes a three-level voltage waveform in each of the output of the input H-bridge and the input of the output H-bridge,
wherein the controller is operable to cause a transition from the TPS mode of operation to the DPS mode of operation in response to an expected power output of the DAB converter in the TPS mode of operation being equal to an expected power output of the DAB converter in the DPS mode of operation in combination with a detected increase in the power consumption of the load.

Assignees

• Hella Gmbh & Co Kgaa

Inventors

• Taylor Allan Ray
• Brown Alan Wayne
• Johnson Philip Michael

Classifications

• B60L50/66

  Arrangements of batteries · CPC title

• H02M1/0058

  by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero (using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826) · CPC title

• H02M1/0032

  Control circuits allowing low power mode operation, e.g. in standby mode · CPC title

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title

• B60L2210/30

  AC to DC converters · CPC title