Phase-shift autotransformer, multi-pulse rectifier systems and fast charging

Patent metadata

Field	Value
Publication number	US-11450477-B2
Application number	US-202016836834-A
Country	US
Kind code	B2
Filing date	Mar 31, 2020
Priority date	Mar 31, 2020
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

The present disclosure relates to systems and configurations for phase-shift autotransformers and multi-pulse rectifiers. A phase-shift autotransformer includes a wiring configuration for first, second and third magnetic cores, the wiring configuration including primary input and phase-shift windings. The primary input windings are configured to provide a first and second primary input inductances, and phase-shift windings of the wiring configuration are configured to provide multiple inductances for each phase-shift winding. A multi-pulse rectifier is provided including a phase-shifting autotransformer, a diode bridge rectifier configuration coupled to output of the autotransformer and a filtering capacitor coupled to the diode bridge rectifier. Other embodiments are directed to use of the multi-use rectifier system with vehicle charging station, such as an Electric Vehicle Supply Equipment (EVSE).

First claim

What is claimed is:

1. A phase-shift autotransformer comprising:
a first magnetic core, a second magnetic core and a third magnetic core;
a wiring configuration for the first, second and third magnetic cores, wherein the wiring configuration includes primary input and phase-shift windings;
an input coupled to the wiring configuration, the input configured to receive AC input; and
an output coupled to the wiring configuration, the output configured to provide six-phase voltage output,
wherein the primary input windings of the wiring configuration and the first, second and third magnetic cores are configured to provide a first primary input inductance, a second primary input inductance, and a third primary input inductance,
wherein the phase-shift windings of the wiring configuration and the first, second and third magnetic cores are configured to provide:
a first and second inductance for phase-shift windings of the first magnetic core;
a third and fourth inductance for phase-shift windings of the second magnetic core; and
a fifth and sixth inductance for phase-shift windings of the third magnetic core, and

wherein output of the first primary inductance is coupled to or between the third and fourth inductance for phase-shift windings of the second magnetic core, output of the second primary inductance is coupled to or between the fifth and sixth inductance for phase-shift windings of the third magnetic core, and output of the third primary inductance is coupled to or between the first and second inductance for phase-shift windings of the first magnetic core.

2. The phase-shift autotransformer of claim 1 , wherein the first magnetic core, the second magnetic core and the third magnetic core include at least one of a five-column core and E-type core.

3. The phase-shift autotransformer of claim 1 , wherein phase angle of AC input voltage and current at each phase is shifted by the first primary input inductance, the second primary input inductance, and the third primary input inductance of the primary input windings of the wiring configuration.

4. The phase-shift autotransformer of claim 1 , wherein the phase-shift windings of the wiring configuration and the first, second and third magnetic cores are configured to provide two voltage components for each core.

5. The phase-shift autotransformer of claim 1 , wherein the first magnetic core, the second magnetic core, the third magnetic core and the wiring configuration are configured to provide a capacity rating of about 10% of output power for a rectifier.

6. The phase-shift autotransformer of claim 1 , wherein the output of the autotransformer is configured to output six-phase output to a multi-pulse rectifier.

7. The phase-shift autotransformer of claim 1 , wherein the first magnetic core, the second magnetic core, the third magnetic core and the wiring configuration are configured to provide a total kVA rating of about 9% output power.

8. A multi-pulse rectifier system comprising:
a phase-shift autotransformer including
a first magnetic core, a second magnetic core and a third magnetic core;
a wiring configuration for the first, second and third magnetic cores, wherein the wiring configuration includes primary input and phase-shift windings;
an input coupled to the wiring configuration, the input configured to receive AC input; and
an output coupled to the wiring configuration, the output configured to provide six-phase voltage output;
a diode bridge rectifier configuration coupled to the output; and
a filtering capacitor coupled to the diode bridge rectifier,

wherein the primary input windings of the wiring configuration and the first, second and third magnetic cores are configured to provide a first primary input inductance, a second primary input inductance, and a third primary input inductance,
wherein the phase-shift windings of the wiring configuration and the first, second and third magnetic cores are configured to provide:
a first and second inductance for phase-shift windings of the first magnetic core;
a third and fourth inductance for phase-shift windings of the second magnetic core; and
a fifth and sixth inductance for phase-shift windings of the third magnetic core, and

wherein output of the first primary inductance is coupled to or between the third and fourth inductance for phase-shift windings of the second magnetic core, output of the second primary inductance is coupled to or between the fifth and sixth inductance for phase-shift windings of the third magnetic core, and output of the third primary inductance is coupled to or between the first and second inductance for phase-shift windings of the first magnetic core.

9. The multi-pulse rectifier system of claim 8 , wherein the first magnetic core, the second magnetic core and the third magnetic core include at least one of a five-column core and E-type core.

10. The multi-pulse rectifier system of claim 8 , wherein a phase angle of AC input voltage and current at each phase is shifted by the first primary input inductance, the second primary input inductance, and the third primary input inductance of the primary input windings of the wiring configuration.

11. The multi-pulse rectifier system of claim 8 , wherein the phase-shift windings of the wiring configuration and the first, second and third magnetic cores are configured to provide two voltage components for each core.

12. The multi-pulse rectifier system of claim 8 , wherein the first magnetic core, the second magnetic core, the third magnetic core and the wiring configuration are configured to provide a capacity rating of about 10% of output power for a rectifier.

13. The multi-pulse rectifier system of claim 8 , wherein the output of the autotransformer is configured to output six-phase output to a multi-pulse rectifier.

14. The multi-pulse rectifier system of claim 8 , wherein the first magnetic core, the second magnetic core, the third magnetic core and the wiring configuration are configured to provide a total kVA rating of about 9% output power.

15. A charging station comprising:
a charging connection; and
a multi-pulse rectifier system coupled to the charging connection, the multi-pulse rectifier system including a phase-shift autotransformer, the phase-shift autotransformer including:
a first magnetic core, a second magnetic core and a third magnetic core;
a wiring configuration for the first, second and third magnetic cores, wherein the wiring configuration includes primary input and phase-shift windings;
an input coupled to the wiring configuration, the input configured to receive AC input; and
an output coupled to the wiring configuration, the output configured to provide six-phase voltage output; and

a diode bridge rectifier configuration coupled to the output; and
a filtering capacitor coupled to the diode bridge rectifier,
wherein the primary input windings of the wiring configuration and the first, second and third magnetic cores are configured to provide a first primary input inductance, a second primary input inductance, and a third primary input inductance,
wherein the phase-shift windings of the wiring configuration and the first, second and third magnetic cores are configured to provide:
a first and second inductance for phase-shift windings of the first magnetic core;
a third and fourth inductance for phase-shift windings of the second magnetic core; and
a fifth and sixth inductance for phase-shift windings of the third magnetic core, and

wherein output of the first primary inductance is coupled to or between the third and fourth inductance for phase-shift windings of the second

Assignees

• Karma Automotive Llc

Inventors

• Yu Xiaohang
• Tang Lixin
• Niu Geng

Classifications

• H01F17/043

  with two, usually identical or nearly identical parts enclosing completely the coil (pot cores) · CPC title

• H02M7/04

  by static converters · CPC title

• H02M1/4208

  Arrangements for improving power factor of AC input · CPC title

• Y02T10/70

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

• B60L53/16

  Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles · CPC title