Method and system for balancing multi-phase LLC power converter with switch-controlled capacitors

Patent metadata

Field	Value
Publication number	US-11990842-B2
Application number	US-202017425621-A
Country	US
Kind code	B2
Filing date	Jan 24, 2020
Priority date	Jan 24, 2019
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

A multi-phase LLC power converter comprises a plurality of LLC phases each including a resonant tank and a switching stage. The resonant tank includes a resonant inductor, a resonant capacitor, and a parallel inductance. The switching stage switches an input power at an operating frequency to apply a switched power to the resonant tank, with the switched power approximating an alternating current (AC) waveform having a switching frequency. A secondary-side controller varies the switching frequency to control an output voltage of the multi-phase LLC power converter. A primary-side controller measures primary-side currents, calculates an initial switch-controlled capacitor (SCC) conduction phase angle for each of the LLC phases, and operates an SCC switch in accordance with an SCC conduction phase angle to adjust the capacitance of the resonant capacitor of an LLC phase to cause each of the LLC phases to have equal resonant frequencies.

First claim

What is claimed is:

1. A method of operating a multi-phase LLC power converter comprising:
switching an input power at a switching frequency by a switching stage of each of a plurality of LLC phases to apply a switched power to a resonant tank having a resonant inductor, a resonant capacitor, and a parallel inductance, the switched power approximating an alternating current (AC) waveform having a switching frequency;
varying the switching frequency to control an output voltage of the multi-phase LLC power converter;
calculating a switch-controlled capacitor (SCC) conduction phase angle for each of the LLC phases to cause each of the LLC phases to have equal resonant frequencies; [and] adjusting a capacitance of the resonant capacitor of at least one of the plurality of LLC phases by operating an SCC switch in accordance with an associated one of the SCC conduction phase angles;
measuring a primary-side current in the resonant tank of each of the LLC phases; and
adjusting the SCC conduction phase angle for one of the LLC phases having a primary-side current that is different from a primary-side current of another one of the LLC phases, wherein adjusting the SCC conduction phase angle for the one of the LLC phases having the primary-side current that is different from the primary-side current of a different one of the LLC phases further comprises at least one of:
adjusting the SCC conduction phase angle for the one of the LLC phases in response to the primary-side current of the one of the LLC phases being different from the primary-side current of another one of the LLC phases for a time exceeding a first timing threshold; or
adjusting the one of the one of the LLC phases in a first direction and adjusting the other one of the LLC phases in a second direction opposite of the first direction in response to the primary-side current of the one of the LLC phases being different from the primary-side current of the different one of the LLC phases for a time exceeding a second timing threshold.

2. The method of claim 1 , wherein operating the SCC switch in accordance with the associated one of the SCC conduction phase angles further comprises driving the SCC switch to a conductive state for a period of time symmetrical about a zero-crossing of a primary-side current in the at least one of the plurality of LLC phases.

3. The method of claim 1 , further comprising enabling a number of LLC phases of the LLC power converter, with the number of LLC phases enabled being only as many as are needed to satisfy an output current of the multi-phase LLC power converter.

4. A multi-phase LLC power converter comprising:
a plurality of LLC phases, each of the LLC phases comprising a resonant tank and a switching stage, the resonant tank including a resonant inductor, a resonant capacitor, and a parallel inductance, and the switching stage configured to switch an input power at an operating frequency to apply a switched power to the resonant tank, the switched power approximating an alternating current (AC) waveform having a switching frequency,
a secondary-side controller configured to vary the switching frequency to control an output voltage of the multi-phase LLC power converter; and
a primary-side controller configured to:
calculate an initial switch-controlled capacitor (SCC) conduction phase angle for each of the LLC phases to cause each of the LLC phases to have equal resonant frequencies;
operate an SCC switch in accordance with an associated one of the SCC conduction phase angles to adjust the capacitance of the resonant capacitor of at least one of the plurality of LLC phases;
measure a primary-side current in the resonant tank of each of the LLC phases; and
adjust the SCC conduction phase angle for one of the LLC phases having a primary-side current that is different from a primary-side current of another one of the LLC phases,

wherein adjusting the SCC conduction phase angle for the one of the LLC phases having the primary-side current that is different from the primary-side current of a different one of the LLC phases further comprises at least one of:
adjusting the SCC conduction phase angle for the one of the LLC phases in response to the primary-side current of the one of the LLC phases being different from the primary-side current of another one of the LLC phases for a time exceeding a first timing threshold; or
adjusting the one of the one of the LLC phases in a first direction and adjusting the other one of the LLC phases in a second direction opposite of the first direction in response to the primary-side current of the one of the LLC phases being different from the primary-side current of the different one of the LLC phases for a time exceeding a second timing threshold.

5. The power converter of claim 4 , wherein operating the SCC switch in accordance with the associated one of the SCC conduction phase angles includes driving the SCC switch to a conductive state for a period of time symmetrical about a zero-crossing of a primary-side current in the at least one of the plurality of LLC phases.

6. The power converter of claim 4 , wherein the switching stage of each of the plurality of LLC phases comprises one or more Gallium Nitride (GaN) high-electron-mobility transistors (HEMTs); and
wherein the switching frequency exceeds 300 kHz.

7. A low-voltage DC-DC converter (LDC) for an electrified vehicle comprising the power converter of claim 4 .

8. The power converter of claim 4 , wherein the power converter has a peak efficiency of at least 96.7% or a full-load efficiency of at least 96.2%.

9. The power converter of claim 4 , wherein the power converter has power density of at least about 3 kW/L.

10. The low-voltage DC-DC converter of claim 7 , wherein the low-voltage DC-DC converter is configured to supply output voltage of 9.0 to 16.0 VDC from the input power of 250 to 430 VDC.

11. A multi-phase LLC power converter comprising:
two LLC phases, each of the two LLC phases comprising a resonant tank and a switching stage, the resonant tank including a resonant inductor, a resonant capacitor, and a parallel inductance, and the switching stage configured to switch an input power at an operating frequency to apply a switched power to the resonant tank, the switched power approximating an alternating current (AC) waveform having a switching frequency,
a secondary-side controller configured to vary the switching frequency to control an output voltage of the multi-phase LLC power converter; and
a primary-side controller configured to: operate a switch-controlled capacitor (SCC) switch in accordance with an associated one of the SCC conduction phase angles to adjust the capacitance of the resonant capacitor of at least one of the two LLC phases;
wherein one of the two LLC phases is a reference phase having a fixed SCC conduction phase angle, and wherein the primary-side controller is configured to calculate an SCC conduction phase angle for the other one of the two LLC phases to cause each of the two LLC phases to have equal currents therethrough; and
wherein the SCC conduction phase angle for the other one of the two LLC phases has an initial value matching the fixed SCC conduction phase angle of the one of the two LLC phases, and wherein the primary-side controller is further configured to decrease the SCC conduction phase angle for the other one of the two LLC phases below the fixed SCC conduction phase angle of the one of the two LLC phases to cause each of the two LLC phases to have equal currents therethrough.

12. The multi-phase LLC power converter of claim 11 , wherein the switched power of each of the two LLC phases is 90-degrees out of phase with one-another.

Assignees

• Magna Int Inc
• Magna powertrain gmbh & co kg

Inventors

• Sheng Bo
• Zhou Xiang
• Liu Wenbo
• Chen Yang
• Liu Yan-Fei
• Yurek Andrew
• Iyer Lakshmi Varaha
• Schlager Gerd
• Neudorfhofer Michael
• Baeck Wolfgang

Classifications

• H02M3/33576 Primary

  having at least one active switching element at the secondary side of an isolation transformer · CPC title

• B60L53/20

  characterised by converters located in the vehicle · 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

• B60L2210/10

  DC to DC converters · CPC title

• H02M1/14 Primary

  Arrangements for reducing ripples from DC input or output · CPC title