Integrated dual-output grid-to-vehicle (G2V) and vehicle-to-grid (V2G) onboard charger for plug-in electric vehicles

Patent metadata

Field	Value
Publication number	US-9931951-B2
Application number	US-201514739822-A
Country	US
Kind code	B2
Filing date	Jun 15, 2015
Priority date	Jun 13, 2014
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

An integrated and isolated onboard charger for plug-in electric vehicles, includes an ac-dc converter and a dual-output dc-dc resonant converter, for both HV traction batteries and LV loads. In addition, the integrated and isolated onboard charger may be configured as unidirectional or bidirectional, and is capable of delivering power from HV traction batteries to the grid for vehicle-to-grid (V2G) applications. To increase the power density of the converter, the dual-output DC-DC resonant converter may combine magnetic components of resonant networks into a single three-winding electromagnetically integrated transformer (EMIT). The resonant converter may be configured as a half-bridge topology with split capacitors as the resonant network components to further reduce the size of converter. The integrated charger may be configured for various operating modes, including grid to vehicle (G2V), vehicle to grid (V2G) and high voltage to low voltage, HV-to-LV (H2L) charging.

First claim

What is claimed is:

1. An integrated power electronics interface comprising:
a first stage, the first stage including:
a power factor correction AC-DC converter; and

a second stage integrated DC-DC converter, including:
an LC resonant network including a plurality of resonance capacitors in electrical communication with a three-winding electromagnetic integrated transformer inherently yielding thereby leakage inductance and magnetizing inductance; and
one of a full-bridge rectifier or a half-bridge rectifier in electrical communication with the plurality of resonance capacitors and the three-winding electromagnetic integrated transformer,

wherein the integrated power electronics interface is configured to enable a charging source to charger operational mode and a charger to charging source operational mode,
wherein the charging source to charger operational mode is enabled via the resonance capacitors, the leakage inductance and magnetizing inductance provided by the LC resonant network that includes the three-winding electromagnetic integrated transformer, and
wherein the charger to charging source operational mode is enabled via the resonance capacitors, the leakage inductance and the magnetizing inductance provided by the LC resonant network that includes the three-winding electromagnetic integrated transformer,
wherein a high voltage to low voltage charging operational mode is enabled via the resonance capacitors, the leakage inductance and the magnetizing inductance provided by the LC resonant network that includes the three-winding electromagnetic integrated transformer,
wherein the three-winding transformer is a transformer configured with leakage inductances and magnetizing inductances electromagnetically integrated forming thereby an electromagnetically-integrated transformer,
wherein the electromagnetically integrated transformer includes:
a first EE core defining a base portion, a central leg and first and second peripheral legs;
a second EE core defining a base portion, a central leg and first and second peripheral legs;
a primary winding wound around the central leg of the first EE core between the first peripheral leg and the central leg and between the second peripheral leg and the central leg of the first EE core;
a secondary winding wound around the central leg of the second EE core between the first peripheral leg and the central leg and between the second peripheral leg and the central leg of the second EE core; and
a tertiary winding wound around the central leg of the second EE core between the first peripheral leg and the central leg and between the second peripheral leg and the central leg of the second EE core,
wherein edges of the legs of the first EE core align with edges of the legs of the second EE core,
wherein the tertiary winding is wound on the central leg of the second EE core below the primary winding wound on the central leg of the first EE core and above the secondary winding wound on the central leg of the second EE core,
wherein an adjustable winding gap is formed between a lower edge of the primary winding on the first EE core and an upper edge of the secondary winding on the second EE core, establishing spatial separation between the secondary winding and the primary winding, and
wherein an adjustable winding gap is formed between a lower edge of the primary winding on the first EE core and an upper edge of the tertiary winding on the second EE core, establishing spatial separation between the tertiary winding and the primary winding, or,
wherein edges of the legs of the first EE core align with edges of the legs of the second EE core,
wherein edges of the legs of the first EE core align with edges of the legs of the second EE core,
wherein the tertiary winding is formed concentrically around the secondary winding and both the secondary winding and the tertiary winding are formed concentrically to one another around the central leg of the second EE core,
wherein an adjustable winding gap is formed between a lower edge of the primary winding and an upper edge of the secondary winding on the second EE core, establishing spatial separation between the secondary winding and the primary winding, and
wherein an adjustable winding gap is formed between a lower edge of the primary winding and an upper edge of the tertiary winding on the second EE core, establishing spatial separation between the tertiary winding and the primary winding.

2. The integrated power electronics interface according to claim 1 , wherein the power factor correction AC-DC converter of the first stage is one of (a) a two-stage converter including a diode bridge followed by a power factor DC-DC converter or (b) a single-stage power factor correction AC-DC converter.

3. The integrated power electronics interface according to claim 2 , wherein the diode bridge of the two-stage converter is one of a full-bridge diode bridge or a half-bridge diode bridge.

4. The integrated power electronics interface according to claim 1 ,
wherein edges of the legs of the first EE core align with edges of the legs of the second EE core and the tertiary winding is formed concentrically around the secondary winding and both the secondary winding and the tertiary winding are formed concentrically around the central leg of the second EE core and
wherein the tertiary winding defines an adjustable concentric winding gap with respect to the secondary winding, establishing spatial separation between the tertiary winding and the secondary winding.

5. The integrated power electronics interface according to claim 1 , wherein the first EE core defines lower edges of the first and second side legs and central leg defining the first EE core and the second EE core defines upper edges of the first and second side legs and central leg defining the second EE core,
wherein a central core gap is formed between the lower edge of the central leg of the first EE core and the upper edge of the central leg of the second EE core and a first peripheral core gap is formed between the lower edge of the first side leg of the first EE core and the upper edge of the first side leg of the second EE core and a second peripheral core gap is formed between the lower edge of the second side leg of the first EE core and the upper edge of the second side leg of the second EE core, thereby causing leakage inductance yielded by the electromagnetically integrated transformer.

6. The integrated power electronics interface according to claim 5 , wherein the first peripheral core gap, central core gap and second peripheral core gap are equal to one another.

7. The integrated power electronics interface according to claim 1 , wherein the first stage AC-DC converter is selected from the group consisting of:
(a) a bidirectional half bridge converter;
(b) a bidirectional full bridge converter;
(c) a bidirectional totem pole converter; and
(d) a bidirectional interleaved totem pole converter.

8. The integrated power electronics interface according to claim 1 , wherein the first stage AC-DC converter is selected from the group consisting of:
(a) a single-leg boost converter;
(b) a single-leg buck-boost converter;
(c) an interleaved boost converter;
(d) an interleaved buck-boost converter; and
(e) a single-ended primary-inductor converter (SEPIC) converter.

9. The integrated power electronics interface according to claim 1 ,
wherein a secondary winding is wound around the central leg of the second EE core between the first peripheral leg and the central leg and between the second peripheral leg and the central leg of the second EE core,
wherein a tertiary winding is wound on the central leg of the second EE core below the primary winding wound on the centr

Assignees

• Univ Maryland

Inventors

• Khaligh Alireza
• Tang Yichao

Classifications

• B60L2210/10

  DC to DC converters · CPC title

• Y04S10/126

  the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G] · CPC title

• B60L53/22

  Constructional details or arrangements of charging converters specially adapted for charging electric vehicles · CPC title

• B60L2210/30

  AC to DC converters · CPC title

• H01F38/08

  High-leakage transformers or inductances · CPC title