WO2010119324A2 - Onboard multiphase converter - Google Patents

Onboard multiphase converter Download PDF

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Publication number
WO2010119324A2
WO2010119324A2 PCT/IB2010/000803 IB2010000803W WO2010119324A2 WO 2010119324 A2 WO2010119324 A2 WO 2010119324A2 IB 2010000803 W IB2010000803 W IB 2010000803W WO 2010119324 A2 WO2010119324 A2 WO 2010119324A2
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WO
WIPO (PCT)
Prior art keywords
core
boost
coil
inductance
self
Prior art date
Application number
PCT/IB2010/000803
Other languages
French (fr)
Other versions
WO2010119324A8 (en
WO2010119324A3 (en
Inventor
Hiroo Fuma
Yuji Nishibe
Kota Manabe
Nobuyuki Kitamura
Original Assignee
Toyota Jidosha Kabushiki Kaisha
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Application filed by Toyota Jidosha Kabushiki Kaisha filed Critical Toyota Jidosha Kabushiki Kaisha
Publication of WO2010119324A2 publication Critical patent/WO2010119324A2/en
Publication of WO2010119324A3 publication Critical patent/WO2010119324A3/en
Publication of WO2010119324A8 publication Critical patent/WO2010119324A8/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H02M3/1584—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load with a plurality of power processing stages connected in parallel

Definitions

  • the present invention relates to an onboard multiphase converter which has a plurality of boost coils magnetically coupled to each other and outputs a voltage according to the electromotive force induced in each boost coil.
  • Hybrid vehicles, electrical vehicles and so on that are driven by driving force from a motor are widely used.
  • Such a motor-driven vehicle has a boost converter which boosts the battery voltage and outputs the boosted voltage to a motor drive circuit.
  • the boost converter has a boost inductor, a switching circuit that switches the current flowing through the boost inductor, and so on.
  • the boost inductor generates an induced electromotive force upon switching of the current.
  • the boost converter outputs a boosted voltage, which is the sum of the input voltage and the induced electromotive force, to the motor drive circuit. Therefore, the boost converter can output a voltage higher than the battery voltage to the motor drive circuit.
  • the boost inductor of the boost converter is usually disposed in the engine compartment of a vehicle.
  • the boost inductor has a core and a boost coil that is wound around the core.
  • the capacity of the engine compartment should be increased and the vehicle cabin should be smaller.
  • the present invention reduces the total volume of the cores of the boost inductors for use in an onboard boost converter.
  • a first aspect of the present invention relates to an onboard multiphase converter.
  • the onboard multiphase converter includes a plurality of boost coils, and a switching circuit that switches the current flowing through each boost coil to generate an induced electromotive force in each boost coil, and applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit.
  • the onboard multiphase converter includes: annular self-inductance cores that are provided for each boost coil and on each of which a corresponding the boost coil is wound; and annular mutual inductance cores which are provided for each pair of boost coils selected from the plurality of boost coils, on each of which the paired boost coils are wound and each of which includes a part of each self-inductance core corresponding to the paired boost coils.
  • Each self-inductance core may include a self-inductance adjusting gap that divides a line in the circumferential direction thereof, and each mutual inductance core may include a coupling adjusting gap that divides a line in the circumferential direction thereof.
  • Each self-inductance core may be formed by combining a plurality of linear cores.
  • Each self-inductance core may be formed by combining a columnar core and a U-shaped core.
  • Each U-shaped core may have a self-inductance adjusting gap.
  • a second aspect of the present invention relates to an onboard multiphase converter.
  • the onboard multiphase converter includes a plurality of boost coils, and a switching circuit that switches the current flowing through each boost coil to generate an induced electromotive force in each boost coil, and applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit.
  • the onboard multiphase converter includes: an annular core; coil-wound columnar cores that are provided for each boost coil, each having an end connected to the annular core, and extending toward the center of the annular core; and auxiliary columnar cores that are provided for each coil-wound columnar core, each having a first end connected to a second end of a corresponding one of the coil-wound columnar cores, extending perpendicular to the circumferential direction of the annular core, and having a second end connected to the annular core.
  • Each coil-wound columnar core and the auxiliary columnar core corresponding to the coil-wound columnar core may form an annular self-inductance core on which a corresponding one of the boost coils is wound in conjunction with the annular core, a coupling adjusting gap may be provided among the junction between the coil-wound columnar core and the auxiliary columnar core that form one of the self-inductance cores, and the junctions between the coil-wound columnar cores and the auxiliary columnar cores that form the other self-inductance cores, and each coil-wound columnar core may have a self-inductance adjusting gap that divides a line in the extending direction thereof.
  • the onboard multiphase converter may further include a coupling hub core that is provided in the coupling adjusting gap.
  • the coil-wound columnar core and the auxiliary columnar core of each self-inductance core may form a V-shaped configuration with an angle of 60°, and the plurality of inductance cores may be arranged inside the annular core at intervals of 120° with apexes of the V-shapes located on the side of the center of the annular core.
  • the total volume of the cores of the boost inductors for use in an onboard boost converter can be reduced.
  • FIG. 1 is a view that illustrates the configuration of a two-phase multiphase converter according to a first embodiment
  • FIG 2 is a view that illustrates the configuration of a first boost inductor and a second boost inductor according to the first embodiment
  • FIG 3 is a view that illustrates a magnetic equivalent circuit corresponding to the first boost inductor and the second boost inductor according to the first embodiment
  • FIG. 4 is a view that illustrates the configuration of a three-phase multiphase converter according to a second embodiment
  • FIGs. 5A to 5D are views that illustrate the configuration of a boost inductor block according to the second embodiment
  • FIG 6 is a view that illustrates a magnetic equivalent circuit corresponding to the boost inductor block according to the second embodiment
  • FIGs. 7A and 7B are views that illustrate the configuration of a boost inductor block according to a modification; and FIGs. 8A and 8B are views that illustrate the configuration of a boost inductor block without a coupling hub core.
  • FIG. 1 shows the configuration of a two-phase multiphase converter according to a first embodiment of the present invention.
  • the two-phase multiphase converter has two boost inductors magnetically coupled with each other and controls the switching of the currents that flow through the inductors at different times.
  • a voltage according to the electromotive force induced in each boost inductor is output from output terminals.
  • the configuration of the two-phase multiphase converter is described below.
  • a first end of an upper switch 16-1 is connected to a first end of a lower switch 18-1.
  • a second end of the lower switch 18-1 is connected to the negative terminal of a battery 10, and a capacitor 20 is connected between a second end of the upper switch 16-1 and the second end of the lower switch 18-1.
  • a first end of a first boost inductor 12 is connected to the positive terminal of the battery 10, and a second end of the first boost inductor 12 is connected to the junction between the upper switch 16-1 and the lower switch 18-1.
  • a first end of an upper switch 16-2 is connected to a first end of a lower switch 18-2.
  • a second end of the lower switch 18-2 is connected to the negative terminal of a battery 10, and the capacitor 20 is connected between a second end of the upper switch 16-2 and the second end of the lower switch 18-2.
  • a first end of a second boost inductor 14 is connected to the positive terminal of the battery 10, and a second end of the second boost inductor 14 is connected to the junction between the upper switch 16-2 and the lower switch 18-2.
  • a first end of the capacitor 20 is connected to an output terminal 22, and a second end of the capacitor 20 is connected to an output terminal 24.
  • a vehicle drive circuit 26 that drives a motor generator for driving a vehicle is connected to the output terminals 22 and 24.
  • a first boost inductor 12 and a second boost inductor 14 are magnetically coupled negatively so that the magnetic flux generated in one of them reduces the magnetic flux in the other when cuirent flows from the battery 10 to each boost inductor or when current flows from each boost inductor to the battery 10.
  • Each of the first boost inductor 12 and the second boost inductor 14 is represented by an inductor in which a coupled section aL and a separate section (l-a)L are connected in series.
  • a represents the coupling factor, which ranges in value from 0 to 1.
  • the coupling factor “a” represents the degree to which the induced electromotive force in the first boost inductor 12 contributes to the voltage between the terminals of the second boost inductor 14 and the degTee to which the induced electromotive force in the second boost inductor 14 contributes to the voltage between the terminals of the first boost inductor 12. That is, L represents the self-inductance of each boost inductor, and the coupled section aL represents the mutual inductance of the first boost inductor 12 and the second boost inductor 14.
  • the dots shown at one side of each of the coupled sections aL in FIG 1 mean that when an induced electromotive force having a positive polarity on the side of the terminal with the dot is generated in one of the coupled sections aL, an induced electromotive force having a positive polarity at the terminal with the dot is generated in the other coupled section aL.
  • FIG. 1 The circuit in FIG. 1 is shown as an equivalent circuit, and the actual first boost inductor 12 and second boost inductor 14 may be configured to be magnetically coupled in a distributed manner at any part of the coil wires thereof.
  • a control unit 28 controls on and off of each switch.
  • the lower switch 18-1 When the lower switch 18-1 is turned on, current flows from the positive terminal of the battery 10 to the first boost inductor 12. Then, when the lower switch 18-1 is turned off, an induced electromotive force based on the change in current is generated in the first boost inductor 12. Then, when the upper switch 16-1 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the first boost inductor 12 is applied to the capacitor 20.
  • the control of the switches by the control unit 28 enables the capacitor 20 to be charged at a voltage Vh which is higher than the battery voltage Vb. Also, the control of the switches by the control unit 28 enables the higher voltage Vh to be output through the output terminals 22 and 24 to the vehicle drive circuit 26. In addition, the voltage Vh that is output to the vehicle drive circuit 26 may be adjusted by changing the times at which the switches are controlled. [0027] Therefore, it is possible to adjust the output electric power from the two-phase multiphase converter to adjust the voltage supplied to the vehicle drive circuit 26 depending on the control of the operation of the vehicle.
  • the vehicle drive circuit 26 generates accelerating torque in the motor generator to accelerate the vehicle or generates braking torque in the motor generator to decelerate the vehicle based on the voltage output from the two-phase multiphase converter.
  • Each boost inductor is constituted of a core and a boost coil that is wound around the core.
  • the use of a material such as dust core, ferrite, or amorphous for the core is preferred.
  • the separate section (l-a)L of the first boost inductor 12 is constituted of a first ring-shaped core 30, and a first boost coil 32 that is wound around the first ring-shaped core 30.
  • the first ring-shaped core 30 is of a square external shape formed by four linear cores 30-1 to 30-4.
  • a self-inductance adjusting gap 34 is provided between the linear core 30-4 and the linear core 30-1.
  • the ring shape of the first ring-shaped core 30 is not limited to square and the first ring-shaped core 30 may be of any general ring shape such as annular or polygonal.
  • first ring-shaped core 30 may have any cross-sectional shape perpendicular to the circumferential direction thereof such as circular or square.
  • the first boost coil 32 is wound around the linear core 30-1 such that it passes through the inside of the first ring-shaped core 30.
  • the separate section (l-a)L of the first boost inductor 14 is constituted of a second ring-shaped core 36, and a second boost coil 38 that is wound around the second ring-shaped core 36.
  • the second ring-shaped core 36 is of a square external shape that is formed by four linear cores 36-1 to 36-4.
  • a self-inductance adjusting gap 40 is provided between the linear core 36-4 and the linear core 36-1.
  • the ring shape of the second ring-shaped core 36 is not limited to square, and the second ring-shaped core 36 may be of any general ring shape such as annular or polygonal.
  • the second ring-shaped core 36 may have any cross-sectional shape perpendicular to the circumferential direction thereof such as circular or square.
  • the second boost coil 38 is wound around the linear core 36-3 such that it passes through the inside of the first ring-shaped core 36.
  • the first ring-shaped core 30 and the second ring-shaped core 36 are disposed such that the linear core 30-1 and the linear core 36-3 are on the same straight line and the linear core 30-3 and the linear core 36-1 are on the same straight line.
  • the linear core 30-1 has a coupling projection 30-5 that extends toward the second ring-shaped core 36 from the portion defining the self-inductance adjusting gap
  • the linear core 30-3 has a coupling projection 30-6 that extends toward the second ring-shaped core 36 from the portion in contact with the linear core 30-4.
  • the linear core 36-1 has a coupling projection 36-5 that extends toward the first ring-shaped core 30 from the portion defining the self-inductance adjusting gap 40 in conjunction with the linear core 36-4.
  • the linear core 36-3 has a coupling projection 36-6 that extends toward the first ring-shaped core 30 from the portion in contact with the linear core 36-4,
  • the end face of the coupling projection 30-5 is opposite end face of the coupling projection 36-6, and both define a coupling adjusting gap 42 between the respective end faces.
  • the end face of the coupling projection 30-6 is opposite the end face of the coupling projection 36-5, and both define a coupling adjusting gap 44 between the respective end faces.
  • Each of the first ring-shaped core 30 and the second ring-shaped core 36 forms a magnetic path along its circumferential direction.
  • the first ring-shaped core 30 and the second ring-shaped core 36 are magnetically coupled via the coupling adjusting gaps 42 and 44 to form a magnetic path along the linear cores 30-1, 30-2, 30-3, 36-1,
  • the first boost coil 32 generates a coupled magnetic flux that is closed along the path formed by the linear cores 30-1, 30-2, 30-3, 36-1, 36-2, and 36-3 and that interlinks with the second boost coil 38 in addition to a self-interlinkage magnetic flux that is closed along the circumferential direction of the first ring-shaped core 30 when current flows through the first boost coil 32.
  • the second boost coil 38 generates a coupled magnetic flux that is closed along the path formed by the linear core 36-3, 36-2, 36-1, 30-3, 30-2 and 30-1 and that interlinks with the first boost coil 32 in addition to a self-interlinkage magnetic flux that is closed along the circumferential direction of the second ring-shaped core 36 when current flows through the second boost coil 38.
  • the coupled sections aL of the first boost inductor 12 and the second boost inductor 14 may be constructed.
  • the self-inductance L of the first boost inductor 12 and the second boost inductor 14 may be adjusted by changing the gap spatial volume (the length, width or the like in the direction of the magnetic path) of the self-inductance adjusting gaps 34 and 40.
  • the mutual inductance aL of the first boost inductor 12 and the second boost inductor 14 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 42 and 44.
  • FIG 3 is obtained.
  • Magnetic resistances RmI-I and Rml-2 are connected in parallel to magnetomotive force sources FLl and FL2, respectively.
  • a magnetic resistance Rm2-1 is connected between the positive terminal of the magnetomotive force source FLl and the positive terminal of the magnetomotive force source FL2.
  • a magnetic resistance Rm2-2 is connected between the negative terminal of the magnetomotive force source FLl and the negative terminal of the magnetomotive force source FL2.
  • the magnetomotive force sources FLl and FL2 correspond to the first boost coil 32 and the second boost coil 38, respectively.
  • the magnetic resistances RmI-I and Rml-2 correspond to the self-inductance adjusting gaps 34 and 40, respectively.
  • the magnetic resistances Rm2-1 and Rm2-2 correspond to the coupling adjusting gaps 44 and 42, respectively.
  • Each magnetomotive force is determined by the number of turns of the boost coil and the current value, and the magnitude of each magnetic resistance is determined by the magnetic permeability of the gap, the size of the gap and so on.
  • the use of the magnetic equivalent circuit facilitates the design of the first boost inductor 12 and the second boost inductor 14.
  • the current flowing through a boost inductor includes a DC component and a ripple component.
  • the ripple component contributes to the generation of induced electromotive force in the boost inductor, that is, boosting operation. Therefore, the DC component of the current flowing through the boost inductor may be reduced, thereby allowing a reduction in the current flowing through the boost inductor without deteriorating the boosting performance of the two-phase multiphase converter.
  • the first boost inductor 12 and the second boost inductor 14 are magnetically coupled negatively to reduce the DC component of the current that flows through each boost inductor.
  • the magnitude of the current that flows through the boost inductors may be reduced without deteriorating the boosting performance thereof.
  • the saturation threshold value may be decreased and the volume of the cores may be reduced accordingly.
  • the core for the separate section (l-a)L and the core for the coupled section aL are not coupled with each other and provided separately to construct the first boost inductor 12 and the second boost inductor 14.
  • the first ring-shaped core 30 and the second ring-shaped core 36 are magnetically coupled to form a path for the coupled magnetic flux.
  • the coupled magnetic flux flows through the paths for the self-interlinkage magnetic fluxes of the first boost inductor 12 and the second boost inductor 14. Therefore, there is no need to separately provide cores for the coupled section of the first boost inductor 12 and the coupled section of the second boost inductor 14, and the volume of the cores that are included in the two-phase multiphase converter may be reduced accordingly.
  • the volume ratio determined by the ratio of the number of turns of the coupled section aL and the separate section (l-a)L, which is the square root of a/(l-a), is 0.5.
  • the total volume of the first boost inductor 12 and the second boost inductor 14 may be reduced to approximately two-thirds in this embodiment, in which the volumes of the two coupled sections aL are reduced.
  • FIG 4 shows the configuration of a three-phase multiphase converter according to the second embodiment.
  • the three-phase multiphase converter has three boost inductors that are magnetically coupled with each other, and controls the switching of the currents that flow through the boost inductors at different times.
  • the same elements as those of the two-phase multiphase converter shown in FIG 1 are designated by the same reference numerals and their description is not repeated.
  • the three-phase multiphase converter may be constructed by adding a third boost inductor 46, an upper switch 16-3, and a lower switch 18-3 to the two-phase multiphase converter.
  • a first end of an upper switch 16-3 is connected to a first end of a lower switch 18-3.
  • a second end of the lower switch 18-3 is connected to the negative terminal of the battery 10, and a second end of the upper switch 16-3 and the second end of the lower switch 18-3 are connected to the opposite ends of the capacitor 20.
  • a first end of a third boost inductor 46 is connected to the positive terminal of the battery 10, and a second end of the third boost inductor 46 is connected to the junction between the upper switch 16-3 and the lower switch 18-3.
  • the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 are magnetically coupled negatively so that the magnetic flux generated in one of the boost inductors reduces the magnetic flux in the other two boost inductors when current flows from the battery 10 to each boost inductor or when a current flows from each boost inductor to the battery 10.
  • Each of the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 is represented by an inductor in which two coupled sections aL and a separate section (l-2a)L are connected in series.
  • "a” represents the coupling factor, which ranges in value from 0 to 0.5.
  • the coupling factor "a" represents the degree to which the'induced electromotive force of one boost inductor contributes to the induced electromotive forces of the other two boost inductors. That is, L represents the self-inductance of each boost inductor, and the coupled section aL represents the mutual inductance between two of the three boost inductors.
  • the circuit in FlG 4 is shown as an equivalent circuit, and the actual first boost inductor 12, second boost inductor 14, and third boost inductor 46 may be configured to be magnetically coupled in a distributed manner at any part of the coil wires thereof. [0051] The operation of the three-phase multiphase converter is described below.
  • the control unit 28 controls on and off of each switch.
  • the lower switch 18-1 When the lower switch 18-1 is turned on, current flows from the positive terminal of the battery 10 to the first boost inductor 12. Then, when the lower switch 18-1 is turned off, an induced electromotive force based on the change in current is generated in the first boost inductor 12. Then, when the upper switch 16-1 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the first boost inductor 12 is applied to the capacitor 20.
  • the control of the switches by the control unit 28 enables the capacitor 20 to be charged at a voltage Vh which is higher than the battery voltage Vb, and enables a voltage Vh which is higher than the battery voltage Vb to be output from the output terminals 22 and 24 to the vehicle drive circuit 26.
  • the voltage Vh to be output to the vehicle drive circuit 26 can be adjusted by changing the times at which the switches are controlled. Therefore, it is possible to adjust the output electric power from the three-phase multiphase converter to adjust the voltage to be applied to the vehicle drive circuit 26 depending on the control of the operation of the vehicle.
  • FIG. 5A is a front view of a boost inductor block 48 including the boost inductors
  • FIG 5B is a view of the boost inductor block 48 as seen from the right side of FIG. 5A.
  • a core that constitutes the boost inductor block 48 has a comb-shaped core 50 and a coupling core 58 that are shown in FIG 5C and U-shaped cores 60 that is shown in FIG 5D.
  • the comb-shaped core 50 is constituted of a linear connecting core 52, and columnar cores 54-1 to 54-3 that extend perpendicular to the extending direction of the connecting core 52 and each having a first end joined to the opposite ends and center of the connecting core 52.
  • the coupling core 58 defines coupling adjusting gaps 56 in conjunction with second ends of the columnar cores and is disposed parallel to the connecting core 52.
  • a first boost coil 64-1, a second boost coil 64-2, and a third boost coil 64-3 are wound around the columnar cores 54-1, 54-2 and 54-3, respectively.
  • each U-shaped core 60 has a self-inductance adjusting gap 62.
  • the cores have a square cross-sectional shape perpendicular to the extending direction thereof, the shape may be any general shape such as polygonal or circular.
  • Each boost coil generates a self-interlinkage magnetic flux along the columnar core around which the boost coil is wound and the U-shaped core that corresponds to the columnar core when current flows therethrough.
  • magnetic paths are formed, each of which starts from the end of one of the columnar cores defining the coupling adjusting gap 56, passes through the columnar core to the connecting core 52, then from the connecting core 52 through another columnar core to the coupling core 58 via the coupling adjusting gap 56 defined by the distal end of the columnar core, and returns to the starting point in the first columnar core via the coupling adjusting gap 56.
  • each boost coil generates coupled magnetic fluxes that interlink with the other two boost coils when current flows therethrough in addition to a self-interlinkage magnetic flux.
  • the separate section (l-2a)L of each inductor can be constructed.
  • the coupled section aL of each inductor can be constructed.
  • the self-inductance L of each boost inductor may be adjusted by changing the gap spatial volume of the self-inductance adjusting gaps 62.
  • the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 56.
  • FIG. 6 When the boost inductor block 48 is represented by a magnetic equivalent circuit, FIG. 6 is obtained. Magnetic resistances RmI-I to Rml-3 are connected in parallel to the magnetomotive force sources FLl to FL3, respectively. First ends of the magnetic resistances Rm2-1 to Rm2-3 are connected to the positive terminals of the magnetomotive force sources FLl to FL3, respectively. Second ends of the magnetic resistances Rm2-1 to Rm2-3 are connected to one another. [0067] The magnetomotive force sources FLl, FL2, and FL3 correspond to the first boost coil 64-1, the second boost coil 64-2, and the third boost coil 64-3, respectively.
  • the magnetic resistances RmI-I to Rml-3 correspond to the self-inductance adjusting gaps 62 of the U-shaped cores 60 provided for the columnar cores 54-1 to 54-3, respectively.
  • the magnetic resistances Rm2-1 to s Rm2-3 correspond to the coupling adjusting gaps 56 defined by the first ends of the columnar cores 54-1 to 54-3, respectively.
  • the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 are magnetically coupled negatively to each other to reduce the DC component of the current that flows through each boost inductor.
  • the magnitude of the current that flows through each boost inductor may be reduced without deteriorating the boosting performance thereof.
  • the saturation threshold value may be decreased and the volume of the cores can be reduced accordingly.
  • the core for the separate section (l-2a)L and the core for the coupled section aL that form the boost inductor are not coupled to each other, but instead provided separately.
  • six cores in total, the cores for the separate sections of the boost inductors and the cores for the coupled sections between the boost inductors, are required, resulting in a large total volume of the cores.
  • the coupled magnetic fluxes can flow through the paths for the self-interlinkage magnetic fluxes of the boost inductors. Therefore, there is no need to additionally provide cores for coupled sections between the boost inductors, and the total volume of the cores included in the three-phase multiphase converter may be reduced.
  • FIG 7A shows the configuration of a modified boost inductor block 66 according to the embodiment.
  • the boost inductor block 66 is a flat version of the boost inductor block 48 shown in FIG 5.
  • the same elements as those in FIG 5 are designated by the same reference numerals and their description is simplified.
  • FIG 7B shows the state of the boost inductor block 66 with the boost coils removed.
  • the boost inductor block 66 has an annular core 68, a circular coupling hub core 74 that is disposed at the center of the annular core 68, three coil-wound columnar cores 70 that each has a first end that defines a coupling adjusting gap 56 in conjunction with the coupling hub core 74, extends perpendicular to the circumferential direction of annular core 68 from the coupling adjusting gap 56, and has a second end that is joined to the annular core 68, and auxiliary columnar cores 72 that are provided for each of the coil-wound columnar cores 70, each has a first end that is joined to the coil-wound columnar core 70, extends along the circular shape of the coupling hub core 74 to form a coupling adjusting gap 56, extends perpendicular to the circumferential direction of the annular core 68, and has a second end that is joined to the annular core 68.
  • Each of the coil-wound columnar cores 70 and the corresponding auxiliary columnar core 72 form a V-shaped configuration with an angle of 60°, and the V-shapes are arranged inside the annular core 68 at intervals of 120° with the apexes located at the center of the annular core 68, whereby three coil-wound columnar cores 70 and three auxiliary columnar cores 72 are arranged.
  • Each of the auxiliary columnar cores 72 has a self-inductance adjusting gap 62.
  • the first boost coil 64-1, the second boost coil 64-2 and the third boost coil 64-3 are wound around a corresponding one of the coil-wound columnar cores 70.
  • the annular core 68 and each columnar core may have any cross-sectional shape perpendicular to the extending direction thereof such as circular or square.
  • Each boost coil generates a self-interlinkage magnetic flux along the coil-wound columnar core 70 on which the boost coil is wound, the auxiliary columnar core 72 provided for the coil-wound columnar core 70, and the section of the annular core 68 between the coil-wound columnar core 70 and the auxiliary columnar core 72 when a current flows therethrough.
  • magnetic paths are formed, each of which starts from the end of one of the coil-wound columnar cores 70 defining the coupling adjusting gap 56, extends through the coil-wound columnar core 70 to the annular core 68 and then from the annular core 68 through another the coil-wound columnar core 70 to the coupling hub core 74 via the coupling adjusting gap 56 defined by the distal end of the coil-wound columnar core 70, and returns to the starting point in the first coil-wound columnar core 70 via the coupling adjusting gap 56.
  • each boost coil generates, in addition to a self-interlinkage magnetic flux that interlinks with the boost coil, coupled magnetic fluxes that interlink with the other boost coils when current flows through the boost coil.
  • the separate section (l-2a)L of each inductor can be constructed.
  • the coupled section aL of each inductor can be constructed.
  • the self-inductance L of each boost inductor may be adjusted by changing the gap spatial volume of the self-inductance adjusting gaps 62.
  • the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 56.
  • FIG. 6 is obtained as in the case with the boost inductor block 48.
  • the magnetic resistances RmI-I to Rm 1-3 correspond to the self-inductance adjusting gaps 62 of the auxiliary columnar cores 72.
  • the magnetic resistances Rm2-1 and Rm2-2 correspond to the coupling adjusting gaps 56.
  • the coupled magnetic fluxes flow through the paths for the self-interlinkage magnetic fluxes of the boost inductors. Therefore, there is no need to additionally provide cores for coupled sections between the boost inductors, and the total volume of the cores that are included in the three-phase multiphase converter may be reduced.
  • the coupling hub core 74 may be omitted when a desired value is obtained as the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46.
  • FIG 8 shows the configuration of a boost inductor block 76 that does not include a coupling hub core 74.
  • the same elements as those in FIG 7 are designated by the same reference numerals and their description is omitted.
  • the apexes of the v-shapes that are formed by the coil-wound columnar cores 70 and the auxiliary columnar cores 72 are located adjacent to the center of the annular core 68.
  • the value of the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be therefore increased.

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Abstract

An onboard multiphase converter that has a plurality of boost coils (32, 38) includes annular self-inductance cores (30, 36) which are provided for each of the boost coils and on each of which a corresponding one of the boost coils is wound; and annular mutual inductance cores which are provided for each pair of boost coils selected from the plurality of boost coils, on each of which the paired boost coils are wound and each of which includes a art of each self-inductance core corresponding to the paired boost coils. Each of the self-inductance cores and mutual inductance cores has a gap (34, 40, 42, 44) that divides a line in the circumferential direction thereof.

Description

ONBOARD MULTIPHASE CONVERTER
FIELD OF THE INVENTION
[0001] The present invention relates to an onboard multiphase converter which has a plurality of boost coils magnetically coupled to each other and outputs a voltage according to the electromotive force induced in each boost coil.
BACKGROUND OF THE INVENTION
[0002] Hybrid vehicles, electrical vehicles and so on that are driven by driving force from a motor are widely used. Such a motor-driven vehicle has a boost converter which boosts the battery voltage and outputs the boosted voltage to a motor drive circuit.
[0003] The boost converter has a boost inductor, a switching circuit that switches the current flowing through the boost inductor, and so on. The boost inductor generates an induced electromotive force upon switching of the current. The boost converter outputs a boosted voltage, which is the sum of the input voltage and the induced electromotive force, to the motor drive circuit. Therefore, the boost converter can output a voltage higher than the battery voltage to the motor drive circuit.
[0004] The boost inductor of the boost converter is usually disposed in the engine compartment of a vehicle. The boost inductor has a core and a boost coil that is wound around the core. When the volume of the core is large, the capacity of the engine compartment should be increased and the vehicle cabin should be smaller.
SUMMARY OF THE INVENTION [0005] The present invention reduces the total volume of the cores of the boost inductors for use in an onboard boost converter.
[0006] A first aspect of the present invention relates to an onboard multiphase converter. The onboard multiphase converter includes a plurality of boost coils, and a switching circuit that switches the current flowing through each boost coil to generate an induced electromotive force in each boost coil, and applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit. The onboard multiphase converter includes: annular self-inductance cores that are provided for each boost coil and on each of which a corresponding the boost coil is wound; and annular mutual inductance cores which are provided for each pair of boost coils selected from the plurality of boost coils, on each of which the paired boost coils are wound and each of which includes a part of each self-inductance core corresponding to the paired boost coils. [0007] Each self-inductance core may include a self-inductance adjusting gap that divides a line in the circumferential direction thereof, and each mutual inductance core may include a coupling adjusting gap that divides a line in the circumferential direction thereof.
[0008] Each self-inductance core may be formed by combining a plurality of linear cores.
[0009] Each self-inductance core may be formed by combining a columnar core and a U-shaped core.
[0010] Each U-shaped core may have a self-inductance adjusting gap.
[0011] A second aspect of the present invention relates to an onboard multiphase converter. The onboard multiphase converter includes a plurality of boost coils, and a switching circuit that switches the current flowing through each boost coil to generate an induced electromotive force in each boost coil, and applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit. The onboard multiphase converter includes: an annular core; coil-wound columnar cores that are provided for each boost coil, each having an end connected to the annular core, and extending toward the center of the annular core; and auxiliary columnar cores that are provided for each coil-wound columnar core, each having a first end connected to a second end of a corresponding one of the coil-wound columnar cores, extending perpendicular to the circumferential direction of the annular core, and having a second end connected to the annular core.
[0012] Each coil-wound columnar core and the auxiliary columnar core corresponding to the coil-wound columnar core may form an annular self-inductance core on which a corresponding one of the boost coils is wound in conjunction with the annular core, a coupling adjusting gap may be provided among the junction between the coil-wound columnar core and the auxiliary columnar core that form one of the self-inductance cores, and the junctions between the coil-wound columnar cores and the auxiliary columnar cores that form the other self-inductance cores, and each coil-wound columnar core may have a self-inductance adjusting gap that divides a line in the extending direction thereof.
[0013] The onboard multiphase converter may further include a coupling hub core that is provided in the coupling adjusting gap.
[0014] The coil-wound columnar core and the auxiliary columnar core of each self-inductance core may form a V-shaped configuration with an angle of 60°, and the plurality of inductance cores may be arranged inside the annular core at intervals of 120° with apexes of the V-shapes located on the side of the center of the annular core.
[0015] According to the present invention, the total volume of the cores of the boost inductors for use in an onboard boost converter can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing and further objects, features and advantages of the invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements and wherein: FIG. 1 is a view that illustrates the configuration of a two-phase multiphase converter according to a first embodiment;
FIG 2 is a view that illustrates the configuration of a first boost inductor and a second boost inductor according to the first embodiment;
FIG 3 is a view that illustrates a magnetic equivalent circuit corresponding to the first boost inductor and the second boost inductor according to the first embodiment;
FIG. 4 is a view that illustrates the configuration of a three-phase multiphase converter according to a second embodiment;
FIGs. 5A to 5D are views that illustrate the configuration of a boost inductor block according to the second embodiment;
FIG 6 is a view that illustrates a magnetic equivalent circuit corresponding to the boost inductor block according to the second embodiment;
FIGs. 7A and 7B are views that illustrate the configuration of a boost inductor block according to a modification; and FIGs. 8A and 8B are views that illustrate the configuration of a boost inductor block without a coupling hub core.
DETAILED DESCRIPTION OF THE EMBODIMENTS [0017] FIG. 1 shows the configuration of a two-phase multiphase converter according to a first embodiment of the present invention. The two-phase multiphase converter has two boost inductors magnetically coupled with each other and controls the switching of the currents that flow through the inductors at different times. A voltage according to the electromotive force induced in each boost inductor is output from output terminals. [0018] The configuration of the two-phase multiphase converter is described below.
A first end of an upper switch 16-1 is connected to a first end of a lower switch 18-1. A second end of the lower switch 18-1 is connected to the negative terminal of a battery 10, and a capacitor 20 is connected between a second end of the upper switch 16-1 and the second end of the lower switch 18-1. A first end of a first boost inductor 12 is connected to the positive terminal of the battery 10, and a second end of the first boost inductor 12 is connected to the junction between the upper switch 16-1 and the lower switch 18-1.
[0019] Similarly, a first end of an upper switch 16-2 is connected to a first end of a lower switch 18-2. A second end of the lower switch 18-2 is connected to the negative terminal of a battery 10, and the capacitor 20 is connected between a second end of the upper switch 16-2 and the second end of the lower switch 18-2. A first end of a second boost inductor 14 is connected to the positive terminal of the battery 10, and a second end of the second boost inductor 14 is connected to the junction between the upper switch 16-2 and the lower switch 18-2.
[0020] A first end of the capacitor 20 is connected to an output terminal 22, and a second end of the capacitor 20 is connected to an output terminal 24. A vehicle drive circuit 26 that drives a motor generator for driving a vehicle is connected to the output terminals 22 and 24. [0021] A first boost inductor 12 and a second boost inductor 14 are magnetically coupled negatively so that the magnetic flux generated in one of them reduces the magnetic flux in the other when cuirent flows from the battery 10 to each boost inductor or when current flows from each boost inductor to the battery 10. Each of the first boost inductor 12 and the second boost inductor 14 is represented by an inductor in which a coupled section aL and a separate section (l-a)L are connected in series. Here, "a" represents the coupling factor, which ranges in value from 0 to 1. The coupling factor "a" represents the degree to which the induced electromotive force in the first boost inductor 12 contributes to the voltage between the terminals of the second boost inductor 14 and the degTee to which the induced electromotive force in the second boost inductor 14 contributes to the voltage between the terminals of the first boost inductor 12. That is, L represents the self-inductance of each boost inductor, and the coupled section aL represents the mutual inductance of the first boost inductor 12 and the second boost inductor 14. The dots shown at one side of each of the coupled sections aL in FIG 1 mean that when an induced electromotive force having a positive polarity on the side of the terminal with the dot is generated in one of the coupled sections aL, an induced electromotive force having a positive polarity at the terminal with the dot is generated in the other coupled section aL.
[0022] The circuit in FIG. 1 is shown as an equivalent circuit, and the actual first boost inductor 12 and second boost inductor 14 may be configured to be magnetically coupled in a distributed manner at any part of the coil wires thereof.
[0023] The operation of the two-phase multiphase converter is described below. A control unit 28 controls on and off of each switch. When the lower switch 18-1 is turned on, current flows from the positive terminal of the battery 10 to the first boost inductor 12. Then, when the lower switch 18-1 is turned off, an induced electromotive force based on the change in current is generated in the first boost inductor 12. Then, when the upper switch 16-1 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the first boost inductor 12 is applied to the capacitor 20.
[0024] When the lower switch 18-2 is turned on, current flows from the positive terminal of the battery 10 to the second boost inductor 14. Then, when the lower switch 18-2 is turned off, an induced electromotive force based on the change in cuirent is generated in the second boost inductor 14. Then, when the upper switch 16-2 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the second boost inductor 14 is applied to the capacitor 20. [0025] The induced electromotive force generated in the first boost inductor 12 induces a voltage in the second boost inductor 14 depending on the coupling factor "a". The induced electromotive force generated in the second boost inductor 14 induces a voltage in the first boost inductor 12 depending on the coupling factor "a".
[0026] According to the above configuration, the control of the switches by the control unit 28 enables the capacitor 20 to be charged at a voltage Vh which is higher than the battery voltage Vb. Also, the control of the switches by the control unit 28 enables the higher voltage Vh to be output through the output terminals 22 and 24 to the vehicle drive circuit 26. In addition, the voltage Vh that is output to the vehicle drive circuit 26 may be adjusted by changing the times at which the switches are controlled. [0027] Therefore, it is possible to adjust the output electric power from the two-phase multiphase converter to adjust the voltage supplied to the vehicle drive circuit 26 depending on the control of the operation of the vehicle. The vehicle drive circuit 26 generates accelerating torque in the motor generator to accelerate the vehicle or generates braking torque in the motor generator to decelerate the vehicle based on the voltage output from the two-phase multiphase converter.
[0028] The configuration of the first boost inductor 12 and the second boost inductor 14 is next described with reference to FIG 2. Each boost inductor is constituted of a core and a boost coil that is wound around the core. The use of a material such as dust core, ferrite, or amorphous for the core is preferred.
[0029] The separate section (l-a)L of the first boost inductor 12 is constituted of a first ring-shaped core 30, and a first boost coil 32 that is wound around the first ring-shaped core 30. In the example that is shown in FIG 2, the first ring-shaped core 30 is of a square external shape formed by four linear cores 30-1 to 30-4. A self-inductance adjusting gap 34 is provided between the linear core 30-4 and the linear core 30-1. The ring shape of the first ring-shaped core 30 is not limited to square and the first ring-shaped core 30 may be of any general ring shape such as annular or polygonal. Also, the first ring-shaped core 30 may have any cross-sectional shape perpendicular to the circumferential direction thereof such as circular or square. The first boost coil 32 is wound around the linear core 30-1 such that it passes through the inside of the first ring-shaped core 30.
[0030] The separate section (l-a)L of the first boost inductor 14 is constituted of a second ring-shaped core 36, and a second boost coil 38 that is wound around the second ring-shaped core 36. In the example shown in FIG. 2, the second ring-shaped core 36 is of a square external shape that is formed by four linear cores 36-1 to 36-4. A self-inductance adjusting gap 40 is provided between the linear core 36-4 and the linear core 36-1. The ring shape of the second ring-shaped core 36 is not limited to square, and the second ring-shaped core 36 may be of any general ring shape such as annular or polygonal. Also, the second ring-shaped core 36 may have any cross-sectional shape perpendicular to the circumferential direction thereof such as circular or square. The second boost coil 38 is wound around the linear core 36-3 such that it passes through the inside of the first ring-shaped core 36.
[0031] The first ring-shaped core 30 and the second ring-shaped core 36 are disposed such that the linear core 30-1 and the linear core 36-3 are on the same straight line and the linear core 30-3 and the linear core 36-1 are on the same straight line.
[0032] The linear core 30-1 has a coupling projection 30-5 that extends toward the second ring-shaped core 36 from the portion defining the self-inductance adjusting gap
34 in conjunction with the linear core 30-4. The linear core 30-3 has a coupling projection 30-6 that extends toward the second ring-shaped core 36 from the portion in contact with the linear core 30-4.
[0033] The linear core 36-1 has a coupling projection 36-5 that extends toward the first ring-shaped core 30 from the portion defining the self-inductance adjusting gap 40 in conjunction with the linear core 36-4. The linear core 36-3 has a coupling projection 36-6 that extends toward the first ring-shaped core 30 from the portion in contact with the linear core 36-4,
[0034] The end face of the coupling projection 30-5 is opposite end face of the coupling projection 36-6, and both define a coupling adjusting gap 42 between the respective end faces. The end face of the coupling projection 30-6 is opposite the end face of the coupling projection 36-5, and both define a coupling adjusting gap 44 between the respective end faces.
[0035] Each of the first ring-shaped core 30 and the second ring-shaped core 36 forms a magnetic path along its circumferential direction. The first ring-shaped core 30 and the second ring-shaped core 36 are magnetically coupled via the coupling adjusting gaps 42 and 44 to form a magnetic path along the linear cores 30-1, 30-2, 30-3, 36-1,
36-2 and 36-3.
[0036] Therefore, the first boost coil 32 generates a coupled magnetic flux that is closed along the path formed by the linear cores 30-1, 30-2, 30-3, 36-1, 36-2, and 36-3 and that interlinks with the second boost coil 38 in addition to a self-interlinkage magnetic flux that is closed along the circumferential direction of the first ring-shaped core 30 when current flows through the first boost coil 32.
[0037] Similarly, the second boost coil 38 generates a coupled magnetic flux that is closed along the path formed by the linear core 36-3, 36-2, 36-1, 30-3, 30-2 and 30-1 and that interlinks with the first boost coil 32 in addition to a self-interlinkage magnetic flux that is closed along the circumferential direction of the second ring-shaped core 36 when current flows through the second boost coil 38.
[0038] As each of the first boost coil 32 and the second boost coil 38 generate a coupled magnetic flux that interlinks with the other coil, the coupled sections aL of the first boost inductor 12 and the second boost inductor 14 may be constructed.
[0039] The self-inductance L of the first boost inductor 12 and the second boost inductor 14 may be adjusted by changing the gap spatial volume (the length, width or the like in the direction of the magnetic path) of the self-inductance adjusting gaps 34 and 40. The mutual inductance aL of the first boost inductor 12 and the second boost inductor 14 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 42 and 44.
[0040] When the first boost inductor 12 and the second boost inductor 14 are represented by a magnetic equivalent circuit, FIG 3 is obtained. Magnetic resistances RmI-I and Rml-2 are connected in parallel to magnetomotive force sources FLl and FL2, respectively. A magnetic resistance Rm2-1 is connected between the positive terminal of the magnetomotive force source FLl and the positive terminal of the magnetomotive force source FL2. A magnetic resistance Rm2-2 is connected between the negative terminal of the magnetomotive force source FLl and the negative terminal of the magnetomotive force source FL2. [0041] The magnetomotive force sources FLl and FL2 correspond to the first boost coil 32 and the second boost coil 38, respectively. The magnetic resistances RmI-I and Rml-2 correspond to the self-inductance adjusting gaps 34 and 40, respectively. The magnetic resistances Rm2-1 and Rm2-2 correspond to the coupling adjusting gaps 44 and 42, respectively. Each magnetomotive force is determined by the number of turns of the boost coil and the current value, and the magnitude of each magnetic resistance is determined by the magnetic permeability of the gap, the size of the gap and so on. The use of the magnetic equivalent circuit facilitates the design of the first boost inductor 12 and the second boost inductor 14.
[0042] In general, in a boost inductor that is constituted of a core and a coil wound around the core, when the current reaches a certain saturation threshold value, magnetic saturation, a phenomenon where the inductance value changes depending on the current, occurs. There is a relation between the volume of the core and the saturation threshold value in which the saturation threshold value increases as the volume of the core increases. Therefore, when the saturation threshold value can be decreased, the volume of the core may be reduced and, accordingly, the volume of the boost inductor may be reduced as well. However, to decrease the saturation threshold value, it is necessary to reduce the current flowing through the boost inductor without deteriorating the boosting performance thereof. [0043] Here, the current flowing through a boost inductor includes a DC component and a ripple component. Of the two components, the ripple component contributes to the generation of induced electromotive force in the boost inductor, that is, boosting operation. Therefore, the DC component of the current flowing through the boost inductor may be reduced, thereby allowing a reduction in the current flowing through the boost inductor without deteriorating the boosting performance of the two-phase multiphase converter.
[0044] Thus, in the two-phase multiphase converter according to this embodiment, the first boost inductor 12 and the second boost inductor 14 are magnetically coupled negatively to reduce the DC component of the current that flows through each boost inductor. By reducing the DC component of the current flowing through the boost inductors, the magnitude of the current that flows through the boost inductors may be reduced without deteriorating the boosting performance thereof. As a result, the saturation threshold value may be decreased and the volume of the cores may be reduced accordingly. [0045] In a conventional two-phase multiphase converter, the core for the separate section (l-a)L and the core for the coupled section aL are not coupled with each other and provided separately to construct the first boost inductor 12 and the second boost inductor 14. Thus, three cores in total, the core for the separate section of the first boost inductor 12, the core for the separate section of the second boost inductor 14, and the core for the coupled section of the first boost inductor 12 and the second boost inductor 14, are required, resulting in a large total volume of the cores.
[0046] In the two-phase multiphase converter according to this embodiment, the first ring-shaped core 30 and the second ring-shaped core 36 are magnetically coupled to form a path for the coupled magnetic flux. Thus, the coupled magnetic flux flows through the paths for the self-interlinkage magnetic fluxes of the first boost inductor 12 and the second boost inductor 14. Therefore, there is no need to separately provide cores for the coupled section of the first boost inductor 12 and the coupled section of the second boost inductor 14, and the volume of the cores that are included in the two-phase multiphase converter may be reduced accordingly.
[00471 For example, when a = 0.2, the volume ratio determined by the ratio of the number of turns of the coupled section aL and the separate section (l-a)L, which is the square root of a/(l-a), is 0.5. Thus, compared to the configuration having two coupled sections aL and two separate sections (l-a)L, the total volume of the first boost inductor 12 and the second boost inductor 14 may be reduced to approximately two-thirds in this embodiment, in which the volumes of the two coupled sections aL are reduced.
[0048] A second embodiment of the present invention is described next. FIG 4 shows the configuration of a three-phase multiphase converter according to the second embodiment. The three-phase multiphase converter has three boost inductors that are magnetically coupled with each other, and controls the switching of the currents that flow through the boost inductors at different times. The same elements as those of the two-phase multiphase converter shown in FIG 1 are designated by the same reference numerals and their description is not repeated.
[0049] The three-phase multiphase converter may be constructed by adding a third boost inductor 46, an upper switch 16-3, and a lower switch 18-3 to the two-phase multiphase converter. A first end of an upper switch 16-3 is connected to a first end of a lower switch 18-3. A second end of the lower switch 18-3 is connected to the negative terminal of the battery 10, and a second end of the upper switch 16-3 and the second end of the lower switch 18-3 are connected to the opposite ends of the capacitor 20. A first end of a third boost inductor 46 is connected to the positive terminal of the battery 10, and a second end of the third boost inductor 46 is connected to the junction between the upper switch 16-3 and the lower switch 18-3.
[0050] The first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 are magnetically coupled negatively so that the magnetic flux generated in one of the boost inductors reduces the magnetic flux in the other two boost inductors when current flows from the battery 10 to each boost inductor or when a current flows from each boost inductor to the battery 10. Each of the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 is represented by an inductor in which two coupled sections aL and a separate section (l-2a)L are connected in series. Here, "a" represents the coupling factor, which ranges in value from 0 to 0.5. The coupling factor "a" represents the degree to which the'induced electromotive force of one boost inductor contributes to the induced electromotive forces of the other two boost inductors. That is, L represents the self-inductance of each boost inductor, and the coupled section aL represents the mutual inductance between two of the three boost inductors. The circuit in FlG 4 is shown as an equivalent circuit, and the actual first boost inductor 12, second boost inductor 14, and third boost inductor 46 may be configured to be magnetically coupled in a distributed manner at any part of the coil wires thereof. [0051] The operation of the three-phase multiphase converter is described below.
The control unit 28 controls on and off of each switch. When the lower switch 18-1 is turned on, current flows from the positive terminal of the battery 10 to the first boost inductor 12. Then, when the lower switch 18-1 is turned off, an induced electromotive force based on the change in current is generated in the first boost inductor 12. Then, when the upper switch 16-1 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the first boost inductor 12 is applied to the capacitor 20.
[0052] When the lower switch 18-2 is turned on, current flows from the positive terminal of the battery 10 to the second boost inductor 14. Then, when the lower switch 18-2 is turned off, an induced electromotive force based on the change in current is generated in the second boost inductor 14. Then, when the upper switch 16-2 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the second boost inductor 14 is applied to the capacitor 20.
[0053] When the lower switch 18-3 is turned on, current flows from the positive terminal of the battery 10 to the third boost inductor 46. Then, when the lower switch 18-3 is turned off, an induced electromotive force based on the change in current is generated in the third boost inductor 46. Then, when the upper switch 16-3 is turned on, the sum of the battery voltage Vb and the induced electromotive force in the second boost inductor 14 is applied to the capacitor 20. [0054] The induced electromotive force generated in each boost inductor induces a voltage in the other two boost inductors depending on the coupling factor "a".
[0055] According to the above configuration, the control of the switches by the control unit 28 enables the capacitor 20 to be charged at a voltage Vh which is higher than the battery voltage Vb, and enables a voltage Vh which is higher than the battery voltage Vb to be output from the output terminals 22 and 24 to the vehicle drive circuit 26. In addition, the voltage Vh to be output to the vehicle drive circuit 26 can be adjusted by changing the times at which the switches are controlled. Therefore, it is possible to adjust the output electric power from the three-phase multiphase converter to adjust the voltage to be applied to the vehicle drive circuit 26 depending on the control of the operation of the vehicle.
[00561 The configuration of the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 is described with reference to FIG 5. FIG. 5A is a front view of a boost inductor block 48 including the boost inductors, and FIG 5B is a view of the boost inductor block 48 as seen from the right side of FIG. 5A. [0057] A core that constitutes the boost inductor block 48 has a comb-shaped core 50 and a coupling core 58 that are shown in FIG 5C and U-shaped cores 60 that is shown in FIG 5D.
[0058] The comb-shaped core 50 is constituted of a linear connecting core 52, and columnar cores 54-1 to 54-3 that extend perpendicular to the extending direction of the connecting core 52 and each having a first end joined to the opposite ends and center of the connecting core 52. The coupling core 58 defines coupling adjusting gaps 56 in conjunction with second ends of the columnar cores and is disposed parallel to the connecting core 52. [0059] A first boost coil 64-1, a second boost coil 64-2, and a third boost coil 64-3 are wound around the columnar cores 54-1, 54-2 and 54-3, respectively.
[0060] The legs of each U-shaped core 60 are joined to each columnar core at points close to the opposite ends thereof. Each of the U-shaped cores 60 has a self-inductance adjusting gap 62. [0061] Here, while the cores have a square cross-sectional shape perpendicular to the extending direction thereof, the shape may be any general shape such as polygonal or circular.
[0062] Each boost coil generates a self-interlinkage magnetic flux along the columnar core around which the boost coil is wound and the U-shaped core that corresponds to the columnar core when current flows therethrough.
[0063] In addition, magnetic paths are formed, each of which starts from the end of one of the columnar cores defining the coupling adjusting gap 56, passes through the columnar core to the connecting core 52, then from the connecting core 52 through another columnar core to the coupling core 58 via the coupling adjusting gap 56 defined by the distal end of the columnar core, and returns to the starting point in the first columnar core via the coupling adjusting gap 56.
[0064] According to the above configuration, each boost coil generates coupled magnetic fluxes that interlink with the other two boost coils when current flows therethrough in addition to a self-interlinkage magnetic flux. As each boost coil generates a self-interlinkage magnetic flux, the separate section (l-2a)L of each inductor can be constructed. Also, as each boost coil generates coupled magnetic fluxes that interlink with other coils, the coupled section aL of each inductor can be constructed.
[0065] The self-inductance L of each boost inductor may be adjusted by changing the gap spatial volume of the self-inductance adjusting gaps 62. The mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 56.
[0066] When the boost inductor block 48 is represented by a magnetic equivalent circuit, FIG. 6 is obtained. Magnetic resistances RmI-I to Rml-3 are connected in parallel to the magnetomotive force sources FLl to FL3, respectively. First ends of the magnetic resistances Rm2-1 to Rm2-3 are connected to the positive terminals of the magnetomotive force sources FLl to FL3, respectively. Second ends of the magnetic resistances Rm2-1 to Rm2-3 are connected to one another. [0067] The magnetomotive force sources FLl, FL2, and FL3 correspond to the first boost coil 64-1, the second boost coil 64-2, and the third boost coil 64-3, respectively. The magnetic resistances RmI-I to Rml-3 correspond to the self-inductance adjusting gaps 62 of the U-shaped cores 60 provided for the columnar cores 54-1 to 54-3, respectively. The magnetic resistances Rm2-1 to s Rm2-3 correspond to the coupling adjusting gaps 56 defined by the first ends of the columnar cores 54-1 to 54-3, respectively.
[0068] The use of the magnetic equivalent circuit facilitates the design of the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46.
[0069] In the three-phase multiphase converter according to this embodiment, the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 are magnetically coupled negatively to each other to reduce the DC component of the current that flows through each boost inductor. By reducing the DC component of the current that flows through each boost inductor, the magnitude of the current that flows through each boost inductor may be reduced without deteriorating the boosting performance thereof. As a result, the saturation threshold value may be decreased and the volume of the cores can be reduced accordingly.
[0070] In a conventional three-phase multiphase converter, the core for the separate section (l-2a)L and the core for the coupled section aL that form the boost inductor are not coupled to each other, but instead provided separately. Thus, six cores in total, the cores for the separate sections of the boost inductors and the cores for the coupled sections between the boost inductors, are required, resulting in a large total volume of the cores.
[0071] According to the boost inductor block 48 of this embodiment, the coupled magnetic fluxes can flow through the paths for the self-interlinkage magnetic fluxes of the boost inductors. Therefore, there is no need to additionally provide cores for coupled sections between the boost inductors, and the total volume of the cores included in the three-phase multiphase converter may be reduced.
[0072] For example, if a = 0.2, the volume ratio that is determined by the ratio of the number of turns of the coupled section aL and the separate section (l-2a)L, which is the square root of a/(l-2a), is 0.58. Thus, compared to the configuration having six coupled section aL and three separate section (l-2a)L, the total volume of the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be reduced to 46% in this embodiment, in which the volumes of the six coupled sections aL are reduced. [0073] A modification of the boost inductor block 48 is next described. FIG 7A shows the configuration of a modified boost inductor block 66 according to the embodiment. The boost inductor block 66 is a flat version of the boost inductor block 48 shown in FIG 5. The same elements as those in FIG 5 are designated by the same reference numerals and their description is simplified. FIG 7B shows the state of the boost inductor block 66 with the boost coils removed.
[0074] The boost inductor block 66 has an annular core 68, a circular coupling hub core 74 that is disposed at the center of the annular core 68, three coil-wound columnar cores 70 that each has a first end that defines a coupling adjusting gap 56 in conjunction with the coupling hub core 74, extends perpendicular to the circumferential direction of annular core 68 from the coupling adjusting gap 56, and has a second end that is joined to the annular core 68, and auxiliary columnar cores 72 that are provided for each of the coil-wound columnar cores 70, each has a first end that is joined to the coil-wound columnar core 70, extends along the circular shape of the coupling hub core 74 to form a coupling adjusting gap 56, extends perpendicular to the circumferential direction of the annular core 68, and has a second end that is joined to the annular core 68. Each of the coil-wound columnar cores 70 and the corresponding auxiliary columnar core 72 form a V-shaped configuration with an angle of 60°, and the V-shapes are arranged inside the annular core 68 at intervals of 120° with the apexes located at the center of the annular core 68, whereby three coil-wound columnar cores 70 and three auxiliary columnar cores 72 are arranged.
[0075] Each of the auxiliary columnar cores 72 has a self-inductance adjusting gap 62. The first boost coil 64-1, the second boost coil 64-2 and the third boost coil 64-3 are wound around a corresponding one of the coil-wound columnar cores 70. [0076] The annular core 68 and each columnar core may have any cross-sectional shape perpendicular to the extending direction thereof such as circular or square.
[0077] Each boost coil generates a self-interlinkage magnetic flux along the coil-wound columnar core 70 on which the boost coil is wound, the auxiliary columnar core 72 provided for the coil-wound columnar core 70, and the section of the annular core 68 between the coil-wound columnar core 70 and the auxiliary columnar core 72 when a current flows therethrough.
[0078] In addition, magnetic paths are formed, each of which starts from the end of one of the coil-wound columnar cores 70 defining the coupling adjusting gap 56, extends through the coil-wound columnar core 70 to the annular core 68 and then from the annular core 68 through another the coil-wound columnar core 70 to the coupling hub core 74 via the coupling adjusting gap 56 defined by the distal end of the coil-wound columnar core 70, and returns to the starting point in the first coil-wound columnar core 70 via the coupling adjusting gap 56.
[0079] Thus, each boost coil generates, in addition to a self-interlinkage magnetic flux that interlinks with the boost coil, coupled magnetic fluxes that interlink with the other boost coils when current flows through the boost coil. As each boost coil generates a self-interlinkage magnetic flux, the separate section (l-2a)L of each inductor can be constructed. Also, as each boost coil generates coupled magnetic fluxes that interlink with other coils, the coupled section aL of each inductor can be constructed. [0080] The self-inductance L of each boost inductor may be adjusted by changing the gap spatial volume of the self-inductance adjusting gaps 62. The mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be adjusted by changing the gap spatial volume of the coupling adjusting gaps 56.
[0081] When the boost inductor block 66 is represented by a magnetic equivalent circuit, FIG. 6 is obtained as in the case with the boost inductor block 48. The magnetic resistances RmI-I to Rm 1-3 correspond to the self-inductance adjusting gaps 62 of the auxiliary columnar cores 72. The magnetic resistances Rm2-1 and Rm2-2 correspond to the coupling adjusting gaps 56.
[0082] According to the modified boost inductor block 66, the coupled magnetic fluxes flow through the paths for the self-interlinkage magnetic fluxes of the boost inductors. Therefore, there is no need to additionally provide cores for coupled sections between the boost inductors, and the total volume of the cores that are included in the three-phase multiphase converter may be reduced.
[0083] In the boost inductor block 66 shown in FIG 7, the coupling hub core 74 may be omitted when a desired value is obtained as the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46.
[0084] FIG 8 shows the configuration of a boost inductor block 76 that does not include a coupling hub core 74. The same elements as those in FIG 7 are designated by the same reference numerals and their description is omitted. The apexes of the v-shapes that are formed by the coil-wound columnar cores 70 and the auxiliary columnar cores 72 are located adjacent to the center of the annular core 68. The value of the mutual inductance aL between the first boost inductor 12, the second boost inductor 14, and the third boost inductor 46 may be therefore increased.
[0085] While the invention has been described with reference to example embodiments thereof, it is to be understood that the invention is not limited to the described embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the disclosed invention are shown in various example combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the scope of the appended claims.

Claims

CLAIMS:
1. An onboard multiphase converter that includes a plurality of boost coils, and a switching circuit that switches the cuirent flowing through each boost coil to generate an induced electromotive force in each boost coil, and wherein the onboard multiphase converter applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit, the onboard multiphase converter comprising: annular self-inductance cores which are provided for each boost coil, on each of which a corresponding the boost coil is wound; and annular mutual inductance cores which are provided for each pair of boost coils selected from the plurality of boost coils, on each of which the paired boost coils are wound and each of which includes a part of each self-inductance core corresponding to the paired boost coils.
2. The onboard multiphase converter according to claim 1, wherein each self-inductance core includes a self-inductance adjusting gap that divides a line in the circumferential direction thereof, and each mutual inductance core includes a coupling adjusting gap that divides a line in the circumferential direction thereof.
3. The onboard multiphase converter according to claim 1 or 2, wherein each self-inductance core is formed by combining a plurality of linear cores.
4. The onboard multiphase converter according to claim 1 or 2, wherein each self-inductance core is formed by combining a columnar core and a U-shaped core.
5. The onboard multiphase converter according to claim 4, wherein each U-shaped core has a self-inductance adjusting gap.
6. An onboard multiphase converter that includes a plurality of boost coils, and a switching circuit that switches the current flowing through each boost coil to generate an induced electromotive force in each boost coil, and wherein the onboard multiphase converter applies an output voltage based on the induced electromotive force generated in each boost coil to a vehicle drive circuit, the onboard multiphase converter comprising: an annular core; coil-wound columnar cores that are provided for each boost coil, each having an end connected to the annular core, and extending toward the center of the annular core; and auxiliary columnar cores that are provided for each coil-wound columnar core, each having a first end connected to a second end of a corresponding one of the coil-wound columnar cores, extending perpendicular to the circumferential direction of the annular core, and having a second end connected to the annular core.
7. The onboard multiphase converter according to claim 6, wherein each coil-wound columnar core and the auxiliary columnar core corresponding to the coil-wound columnar core form an annular self-inductance core on which a corresponding one of the boost coils is wound in conjunction with the annular core, a coupling adjusting gap is provided among the junction between the coil-wound columnar core and the auxiliary columnar core that form one of the self-inductance cores, and the junctions between the coil-wound columnar cores and the auxiliary columnar cores that form the other self-inductance cores, and wherein each coil-wound columnar core has a self-inductance adjusting gap that divides a line in the extending direction thereof.
8. The onboard multiphase converter according to claim 6 or 7, further comprising a coupling hub core that is provided in the coupling adjusting gap.
9. The onboard multiphase converter according to any one of claims 1 to 8, wherein the coil-wound columnar core and the auxiliary columnar core of each self-inductance core form a V-shaped configuration with an angle of 60°, and the plurality of inductance cores are arranged inside the annular core at intervals of
120° with apexes of the V-shapes located on the side of the center of the annular core.
PCT/IB2010/000803 2009-04-16 2010-04-12 Onboard multiphase converter WO2010119324A2 (en)

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