WO2020200747A1 - Three-phase ac to dc power converter - Google Patents

Three-phase ac to dc power converter Download PDF

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Publication number
WO2020200747A1
WO2020200747A1 PCT/EP2020/057180 EP2020057180W WO2020200747A1 WO 2020200747 A1 WO2020200747 A1 WO 2020200747A1 EP 2020057180 W EP2020057180 W EP 2020057180W WO 2020200747 A1 WO2020200747 A1 WO 2020200747A1
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WO
WIPO (PCT)
Prior art keywords
cuk
high frequency
converter
rfc
parallel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2020/057180
Other languages
French (fr)
Inventor
Stefan RAAIJMAKERS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Schweiz AG
Original Assignee
ABB Schweiz AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Schweiz AG filed Critical ABB Schweiz AG
Priority to CN202080026073.1A priority Critical patent/CN113632355A/en
Publication of WO2020200747A1 publication Critical patent/WO2020200747A1/en
Priority to US17/491,544 priority patent/US11837952B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/42Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208Arrangements for improving power factor of AC input
    • H02M1/4216Arrangements for improving power factor of AC input operating from a three-phase input voltage
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/12Arrangements for reducing harmonics from AC input or output
    • H02M1/126Arrangements for reducing harmonics from AC input or output using passive filters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/20Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by converters located in the vehicle
    • B60L53/22Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/0067Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007Plural converter units in cascade
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/32Means for protecting converters other than automatic disconnection
    • H02M1/34Snubber circuits
    • H02M1/348Passive dissipative snubbers
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/42Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208Arrangements for improving power factor of AC input
    • H02M1/4225Arrangements for improving power factor of AC input using a non-isolated boost converter
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/42Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208Arrangements for improving power factor of AC input
    • H02M1/425Arrangements for improving power factor of AC input using a single converter stage both for correction of AC input power factor and generation of a high frequency AC output voltage
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/42Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208Arrangements for improving power factor of AC input
    • H02M1/4258Arrangements for improving power factor of AC input using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M3/00Conversion of DC power input into DC power output
    • H02M3/005Conversion of DC power input into DC power output using Cuk converters
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/12Arrangements for reducing harmonics from AC input or output
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/70Energy storage systems for electromobility, e.g. batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/14Plug-in electric vehicles

Definitions

  • the invention relates to a three-phase alternating current, AC, to direct current, DC, power converter in particular for charging an electrical vehicle, comprising a low frequency diode-based converter.
  • Power converters for charging electrical vehicles are known from prior art and are often referred to as electric vehicle charging station, also called EV charging station, electric recharging point, charging point, charge point, ECS, electronic charging station, or in recent days as EVSE, electric vehicle supply equipment.
  • an EVSE is an element in an infrastructure that supplies electric energy for the recharging of electric vehicles, such as plug-in electric vehicles, including electric cars, neighbourhood electric vehicles and plug-in hybrids, either at home, at public spaces or work.
  • Some electric vehicles have on board converters that can plug into a standard electrical outlet or a high-capacity appliance outlet.
  • Other electrical vehicles either require or can use a charging station that provides electrical conversion, monitoring, or safety functionality.
  • CCS Combined Charging System
  • topologies that are cheap, provide a large output voltage range, are characterized by a high efficient power conversion, a good power factor, THD, total harmonic distortion, on alternating current, AC and/or a good output ripple on direct current, DC.
  • direct current, DC, power converter in particular for charging an electrical vehicle, comprising
  • a boost power factor correction, RFC circuit comprising a low frequency diode-based converter configured for connecting a RFC input of the converter to an AC source, and a RFC inductor and a RFC capacitor connected in series together and in parallel to a RFC output of the converter, further comprising either a high frequency RFC diode and a high frequency PFC switch connected in parallel to the PFC output of the converter or comprising a plurality of high frequency PFC switches each connected in parallel to one of the diodes of the converter,
  • a Cuk converter comprising a Cuk inductor and a first Cuk capacitor connected in series, a second Cuk capacitor and a high frequency Cuk diode connected in parallel to the series connection and forming, via a series connection with the second Cuk capacitor, a Cuk output in particular to which the electrical vehicle can be connected as DC load, and
  • a transformer having a primary side connected in parallel to the PFC capacitor and a secondary side connected in parallel to the Cuk capacitor.
  • a power factor correction, PFC circuit generally increases the power factor of a load thereby improving overall conversion efficiency.
  • the power factor of an AC electrical power system is defined as the ratio of the real power absorbed by the load to the apparent power flowing in the circuit, and is a dimensionless number in the closed interval of -1 to 1.
  • a Cuk converter sometimes incorrectly spelled Cuk, Cuk or Cdk, is a type of DC/DC converter that has an output voltage magnitude that is either greater than or less than the input voltage magnitude.
  • the Cuk converter is essentially a boost converter followed by a buck converter with a capacitor i.e. the first Cuk capacitor to couple the energy.
  • the Cuk converter is named after Slobodan Cuk of the California Institute of Technology, who first presented the design.
  • the Cuk converter is preferably provided as an isolated Cuk converter. Switching frequency for the switches is for example 10kHz.
  • the proposed converter provides the advantage of a constant input
  • the proposed converter advantageously provides a wide range of output voltages. Possible inductors on the AC side see three levels, thereby reducing the input voltage ripple. Due to using the Cuk respectively boost-buck converter, a wide output voltage range
  • the proposed solution is particularly suited for SiC, silicon carbide, and IGBTs as switches and can be implemented by using only one“high” frequency switch and each one“high” frequency diode on the primary and on the secondary side.
  • the proposed converter can be implemented at very low cost but thereby providing high efficiency in conversion.
  • the power path only requires one high frequency RFC switch, one high frequency RFC diode, one high frequency Cuk diode, six low frequency diodes of the diode-based converter, mains frequency, four inductors, RFC and Cuk, as well as two capacitors, RFC and Cuk.
  • the prosed topology does not need any AC voltage or current measurement while only output voltage and current would be sufficient. Control of the switching can very easily done, as it is naturally stable, works with a fixed PWM, pulse width modulation, or slight corrections in case of unclean AC sources.
  • the RFC inductor can be used in discontinuous mode resulting in a good power factor.
  • the plurality of high frequency RFC switches are each connected in parallel to one of the diodes of the converter such solution either provides a good power factor, while it can be uni- or bi directional, with the addition of one extra Cuk switch, as described later.
  • the diodes of the converter are preferably provided as high frequency diodes as well.
  • the term high frequency means in terms of the present application that, for example for a switch, the switch provide faster switching frequency than of overall system frequency, for example of the AC network. In such topology a single high frequency RFC switch can be overtaken by the plurality of high frequency RFC switches using some smart switching strategies.
  • the single high frequency RFC switch is replaced by switching on all the plurality of high frequency RFC switches on the AC side of the diode-based converter. Any remaining duty cycle can be used to perform the RFC function on the AC side by switching the corresponding top and bottom high frequency RFC switches.
  • the top or bottom high frequency RFC switches can be left on, and switched over in between, after which all high frequency RFC switches are switched on again.
  • Such switching results in a good RFC on the AC side and constant current on the DC side.
  • soft-switching techniques that have been used before in Cuk and boost RFC converters can be applied to the proposed topologies. With such version with six high frequency RFC switches on the primary and a high frequency Cuk switch switch on the secondary side, as discussed later, the converter can work bi-directionally.
  • the following implementations allow for further improving RFC and/or THD, total harmonic distortion, by using additional passive trap filter elements and/or passive RFC, additional parallel active harmonic compensation/PFC and/or harmonic compensation by replacing low frequency diodes with active switches.
  • First two options are in particular advantageous depending on the power level and requirements. The latter option uses same power inductors. Therefore, extra costs only occur due to switches and their drivers compared to an additional active filter which would require extra inductors and a capacitor buffer.
  • the RFC capacitor, via the transformer, and the Cuk capacitor are connected to the negative potential of the Cuk output and the PFC inductor is connected, via the transformer, the first Cuk inductor and the second Cuk inductor, to the positive potential of the Cuk output.
  • anode of the high frequency Cuk diode is connected to the negative potential of the Cuk output.
  • the second Cuk inductor is connected to the positive potential of the Cuk output and in series with the first Cuk inductor.
  • the converter comprises a high frequency Cuk switch connected in parallel to the high frequency Cuk diode.
  • the converter comprises three phase inductors each arranged in a respective current path between the PFC input and the low frequency diode-based converter.
  • the converter comprises three trap capacitors and each trap inductors, the trap inductors connected together and in series with each one trap capacitors, whereby each one trap capacitor is connected to a respective phase inductor and the low frequency diode-based converter.
  • the converter comprises three phase capacitors connected to together and to a respective phase of the PFC input.
  • Such embodiments are in particular advantageous for reducing fifth and seventh harmonics, in particular by providing such trap filter thereby improving THD, total harmonic distortion, significantly.
  • THD is a measurement of the harmonic distortion present in a signal and normally defined as the ratio of the sum of the powers of all harmonic components to the power of the fundamental frequency.
  • the converter comprises the high frequency PFC diode and the high frequency PFC switch connected in parallel to the RFC output of the converter, further comprising a second high frequency RFC diode and a second high frequency RFC switch connected in parallel, whereby each the RFC diodes the RFC switches are connected in parallel to the RFC output of the converter.
  • Such embodiment allows for lower voltage rating switches and multi-level switching thereby reducing input and output ripple and/inductance values.
  • the converter comprises the plurality of high frequency RFC switches each connected in parallel to one of the diodes of the converter, further comprising a second high frequency RFC switch connected in parallel to the RFC inductor.
  • the converter comprises the plurality of high frequency RFC switches each connected in parallel to one of the diodes of the converter, further comprising a high frequency Cuk switch connected in parallel to the high frequency Cuk diode, a second frequency Cuk switch and a second high frequency Cuk diode connected in parallel to the second high frequency Cuk switch, whereby each the high frequency Cuk diodes the high frequency Cuk switches are connected in parallel to the series connection of the first Cuk inductor and the Cuk capacitor.
  • a high frequency Cuk switch connected in parallel to the high frequency Cuk diode
  • a second frequency Cuk switch and a second high frequency Cuk diode connected in parallel to the second high frequency Cuk switch
  • Fig. 1 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter according to a preferred embodiment of the invention
  • Fig. 2 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter according to another preferred embodiment of the invention
  • Fig. 3 shows in a schematically drawing a partial view of the power
  • Fig. 4 shows in a schematically drawing a partial view of the power
  • Fig. 5 shows in a schematically drawing a partial view of the power
  • Fig. 1 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter for charging an electrical vehicle 1 according to a preferred embodiment.
  • the converter comprises a boost power factor correction, RFC, circuit 2, a Cuk converter 3 and a transformer 4.
  • the RFC circuit 2 is on one side connected to an AC source 5, such as an AC grid.
  • the RFC circuit 2 is connected to the transformer 4, which is then connected to the Cuk converter 3, to which the electrical vehicle 1 is connected as DC load 6.
  • the three phase RFC circuit 2 comprises a low frequency diode-based converter 7, a high frequency RFC diode 8, a high frequency RFC switch 9, a RFC inductor 10 and a RFC capacitor 11.
  • the high frequency RFC diode 8 and the high frequency RFC switch 9, which is provided as a voltage controlled FET switch, are arranged in parallel and thereby connected in parallel to an output of the diode-based converter 7 such that the anodes as well as the cathodes of the diodes of the diode-based converter 7 and of the high frequency RFC diode 8 are respectively connected together.
  • the RFC inductor 10 has an inductance of 10 mH and the RFC capacitor 11 has a capacitance of 1000 pF are connected in series such that the RFC inductor 10 is connected to the cathodes and the RFC capacitor 11 is connected to the anodes.
  • Fig. 2 shows a further preferred embodiment, wherein, opposite to Fig. 1 , the high frequency RFC diode 8 and the high frequency RFC switch 9 are not connected in parallel to the output of the diode-based converter 7. Instead, each one high frequency RFC switch 9 is connected in parallel to each diode of the diode-based converter 7.
  • the Cuk converter 3 comprises a first Cuk inductor 12 and a Cuk capacitor
  • the first Cuk inductor 12 has an inductance of 10 mH and the Cuk capacitor 13 has a capacitance of 1000 pF.
  • the Cuk converter 12 further comprises a high frequency Cuk diode
  • the anode of the high frequency Cuk diode 14 is connected, via the transformer 4, to the anode of the high frequency RFC diode 8.
  • the Cuk converter 3 further comprises a second Cuk inductor 15 having an inductance of 1000 pH, which is connected to the cathode of the high frequency Cuk diode 14.
  • a second Cuk inductor 15 having an inductance of 1000 pH, which is connected to the cathode of the high frequency Cuk diode 14.
  • the second Cuk inductor 15 and the anode of the high frequency Cuk diode 14 form a Cuk output 16, to which the electrical vehicle 1 is connected as DC load 6.
  • the anode of the high frequency Cuk diode 13 is connected to the negative potential of the Cuk output 16.
  • the further embodiment of Fig. 2 shows a high frequency Cuk switch 17, which is connected in parallel to the high frequency Cuk diode 14.
  • the transformer 4 is connected with its primary side in parallel to the RFC capacitor 11 and with its secondary side in parallel to the Cuk capacitor 13, thereby connecting the RFC circuit 2 and the Cuk converter 3. Such way the Cuk capacitor 13 and the RFC capacitor 11 are connected, via the transformer 4, to the negative potential of the Cuk output 16.
  • the RFC inductor 10 is connected, via the transformer 4 and the first Cuk inductor 11 and the second Cuk inductor 15 to the positive potential of the Cuk output 16.
  • Fig. 3 shows an enlarged respectively partial view of the RFC circuit 2 according to a further preferred embodiment.
  • Phase inductors 18 having each an inductance of 1000 pH are provided in each current path between the AC source 5 and the diode-based converter 7.
  • a trap filter is provided comprising two sets of each three trap capacitors 19 having each a capacitance of 1000 pF and three respective trap inductors 20 having each an inductance of 1000 pH.
  • Each three trap inductors 20 are connected star-like together and in series with each one trap capacitors 19 to one phase between the phase inductors 18 and the converter 7.
  • phase capacitors 21 are provided each having a capacitance of 1000 pF.
  • the phase capacitors 21 are connected star-like together and each to one phase between the phase inductors 18 and the AC source 7.
  • Fig. 4 shows a further embodiment of the RFC circuit 2, whereby a second high frequency RFC diode 22 and a second high frequency PFC switch 23 are provided.
  • the high frequency PFC diode 8 and the second high frequency PFC diode 22 are connected in series and such wise in parallel to the output of the converter 7.
  • the high frequency PFC switch 9 and the second high frequency PFC switch 23 are also connected in series and such wise in parallel to the output of the converter 7.
  • said switches 9, 23 and diodes 8, 22 are star-like interconnected.
  • a further high frequency PFC diode 24 is provided for receding losses
  • the frequency PFC switch 9 is connected in parallel to one of the diodes of the converter 7. Further, the second high frequency PFC switch 23 is connected in parallel to the PFC inductor 10.
  • the Cuk converter 3 comprises a second high frequency Cuk switch 24 and a second high frequency Cuk diode 25.
  • the high frequency Cuk switch 17 and the high frequency Cuk switch 24 are connected in series and such wise parallel to the series connection of the second high frequency Cuk switch 24 and the second high frequency Cuk diode 25, which are connected in parallel to the series connection of the Cuk first inductor 12 and the Cuk capacitor 13.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Rectifiers (AREA)
  • Dc-Dc Converters (AREA)

Abstract

The invention relates to a three-phase alternating current, AC, to direct current, DC, power converter, comprising a boost power factor correction, PFC, circuit (2) comprising a low frequency diode-based converter (7) configured for connecting a PFC input of the converter (7) to an AC source (5), and a PFC inductor (10) and a PFC capacitor (11) connected in series together and in parallel to a PFC output of the converter (7), further comprising either a high frequency PFC diode (8) and a high frequency PFC switch (9) connected in parallel to the PFC output of the converter (7) or comprising a plurality of high frequency PFC switches (9) each connected in parallel to one of the diodes of the converter (7), a Ćuk converter (3) comprising a first Ćuk inductor (12) and a Ćuk capacitor (13) connected in series, a second Ćuk inductor (15) and a high frequency Ćuk diode (14) connected in parallel to the series connection and forming, via a series connection with the second Ćuk inductor (15), a Ćuk output (16) to which a DC load (6) can be connected, and a transformer (4) having a primary side connected in parallel to the PFC capacitor (11) and a secondary side connected in parallel to the Ćuk capacitor (13).

Description

Description
Three-phase AC to DC power converter
Technical Field
[0001 ] The invention relates to a three-phase alternating current, AC, to direct current, DC, power converter in particular for charging an electrical vehicle, comprising a low frequency diode-based converter.
Background Art
[0002] Power converters for charging electrical vehicles are known from prior art and are often referred to as electric vehicle charging station, also called EV charging station, electric recharging point, charging point, charge point, ECS, electronic charging station, or in recent days as EVSE, electric vehicle supply equipment. Generally, an EVSE is an element in an infrastructure that supplies electric energy for the recharging of electric vehicles, such as plug-in electric vehicles, including electric cars, neighbourhood electric vehicles and plug-in hybrids, either at home, at public spaces or work. Some electric vehicles have on board converters that can plug into a standard electrical outlet or a high-capacity appliance outlet. Other electrical vehicles either require or can use a charging station that provides electrical conversion, monitoring, or safety functionality.
[0003] These charging stations are also needed when traveling, and many
support faster charging at higher voltages and currents than are available from residential EVSEs. Public charging stations are typically on-street facilities provided by electric utility companies or located at retail shopping centres, restaurants and parkings, and operated by many private companies. Charging standards encompass Combined Charging System, CCS, which is becoming the universal standard or CHAdeMO besides others.
[0004] There is general aim to constantly provide better power converter
topologies that are cheap, provide a large output voltage range, are characterized by a high efficient power conversion, a good power factor, THD, total harmonic distortion, on alternating current, AC and/or a good output ripple on direct current, DC.
Summary of invention
[0005] It is therefore an object of the invention to provide an improved power converter for charging an electrical vehicle.
[0006] The object of the invention is solved by the features of the independent claims. Preferred embodiments are detailed in the dependent claims.
[0007] Thus, the object is solved by a three-phase alternating current, AC, to
direct current, DC, power converter in particular for charging an electrical vehicle, comprising
a boost power factor correction, RFC, circuit comprising a low frequency diode-based converter configured for connecting a RFC input of the converter to an AC source, and a RFC inductor and a RFC capacitor connected in series together and in parallel to a RFC output of the converter, further comprising either a high frequency RFC diode and a high frequency PFC switch connected in parallel to the PFC output of the converter or comprising a plurality of high frequency PFC switches each connected in parallel to one of the diodes of the converter,
a Cuk converter comprising a Cuk inductor and a first Cuk capacitor connected in series, a second Cuk capacitor and a high frequency Cuk diode connected in parallel to the series connection and forming, via a series connection with the second Cuk capacitor, a Cuk output in particular to which the electrical vehicle can be connected as DC load, and
a transformer having a primary side connected in parallel to the PFC capacitor and a secondary side connected in parallel to the Cuk capacitor.
[0008] It is therefore a key aspect of the invention to combine a three phase
boost PFC circuit with a Cuk converter. A power factor correction, PFC circuit generally increases the power factor of a load thereby improving overall conversion efficiency. The power factor of an AC electrical power system is defined as the ratio of the real power absorbed by the load to the apparent power flowing in the circuit, and is a dimensionless number in the closed interval of -1 to 1. A Cuk converter, sometimes incorrectly spelled Cuk, Cuk or Cdk, is a type of DC/DC converter that has an output voltage magnitude that is either greater than or less than the input voltage magnitude. The Cuk converter is essentially a boost converter followed by a buck converter with a capacitor i.e. the first Cuk capacitor to couple the energy. The Cuk converter is named after Slobodan Cuk of the California Institute of Technology, who first presented the design. The Cuk converter is preferably provided as an isolated Cuk converter. Switching frequency for the switches is for example 10kHz.
[0009] The proposed converter provides the advantage of a constant input
current and constant output current, with inductor current ripple. Even that hard switching may be applied to the switch, the proposed solution helps to improve EMC, electromagnetic compatibility, and input/output ripple requirements. The proposed converter advantageously provides a wide range of output voltages. Possible inductors on the AC side see three levels, thereby reducing the input voltage ripple. Due to using the Cuk respectively boost-buck converter, a wide output voltage range
independent of the input voltage can be achieved. Thus, power conversion efficiency is very high as there is no input rectification or output
rectification. The proposed solution is particularly suited for SiC, silicon carbide, and IGBTs as switches and can be implemented by using only one“high” frequency switch and each one“high” frequency diode on the primary and on the secondary side. Thus, as component count is in addition very low, the proposed converter can be implemented at very low cost but thereby providing high efficiency in conversion.
[0010] In case the high frequency RFC diode and the high frequency RFC switch are connected in parallel to the RFC output of the converter the power path only requires one high frequency RFC switch, one high frequency RFC diode, one high frequency Cuk diode, six low frequency diodes of the diode-based converter, mains frequency, four inductors, RFC and Cuk, as well as two capacitors, RFC and Cuk. The prosed topology does not need any AC voltage or current measurement while only output voltage and current would be sufficient. Control of the switching can very easily done, as it is naturally stable, works with a fixed PWM, pulse width modulation, or slight corrections in case of unclean AC sources. For such‘single’ switch version the RFC inductor can be used in discontinuous mode resulting in a good power factor.
[0011 ] In case the plurality of high frequency RFC switches are each connected in parallel to one of the diodes of the converter such solution either provides a good power factor, while it can be uni- or bi directional, with the addition of one extra Cuk switch, as described later. In such case the diodes of the converter are preferably provided as high frequency diodes as well. The term high frequency means in terms of the present application that, for example for a switch, the switch provide faster switching frequency than of overall system frequency, for example of the AC network. In such topology a single high frequency RFC switch can be overtaken by the plurality of high frequency RFC switches using some smart switching strategies. In other words, the single high frequency RFC switch is replaced by switching on all the plurality of high frequency RFC switches on the AC side of the diode-based converter. Any remaining duty cycle can be used to perform the RFC function on the AC side by switching the corresponding top and bottom high frequency RFC switches. Depending on the direction of the current, after all high frequency RFC switches are on, preferably the top or bottom high frequency RFC switches can be left on, and switched over in between, after which all high frequency RFC switches are switched on again. Such switching results in a good RFC on the AC side and constant current on the DC side. Besides that soft-switching techniques that have been used before in Cuk and boost RFC converters can be applied to the proposed topologies. With such version with six high frequency RFC switches on the primary and a high frequency Cuk switch switch on the secondary side, as discussed later, the converter can work bi-directionally.
[0012] The following implementations allow for further improving RFC and/or THD, total harmonic distortion, by using additional passive trap filter elements and/or passive RFC, additional parallel active harmonic compensation/PFC and/or harmonic compensation by replacing low frequency diodes with active switches. First two options are in particular advantageous depending on the power level and requirements. The latter option uses same power inductors. Therefore, extra costs only occur due to switches and their drivers compared to an additional active filter which would require extra inductors and a capacitor buffer.
[0013] According to a further preferred implementation the RFC capacitor, via the transformer, and the Cuk capacitor are connected to the negative potential of the Cuk output and the PFC inductor is connected, via the transformer, the first Cuk inductor and the second Cuk inductor, to the positive potential of the Cuk output.
[0014] In another preferred implementation the anode of the high frequency Cuk diode is connected to the negative potential of the Cuk output.
[0015] According to a further preferred implementation the second Cuk inductor is connected to the positive potential of the Cuk output and in series with the first Cuk inductor.
[0016] According to a further preferred implementation the converter comprises a high frequency Cuk switch connected in parallel to the high frequency Cuk diode.
[0017] According to another preferred implementation the converter comprises three phase inductors each arranged in a respective current path between the PFC input and the low frequency diode-based converter.
[0018] According to a further preferred implementation the converter comprises three trap capacitors and each trap inductors, the trap inductors connected together and in series with each one trap capacitors, whereby each one trap capacitor is connected to a respective phase inductor and the low frequency diode-based converter.
[0019] According to another preferred implementation the converter comprises three phase capacitors connected to together and to a respective phase of the PFC input. Such embodiments are in particular advantageous for reducing fifth and seventh harmonics, in particular by providing such trap filter thereby improving THD, total harmonic distortion, significantly. THD is a measurement of the harmonic distortion present in a signal and normally defined as the ratio of the sum of the powers of all harmonic components to the power of the fundamental frequency.
[0020] According to a further preferred implementation the converter comprises the high frequency PFC diode and the high frequency PFC switch connected in parallel to the RFC output of the converter, further comprising a second high frequency RFC diode and a second high frequency RFC switch connected in parallel, whereby each the RFC diodes the RFC switches are connected in parallel to the RFC output of the converter.
Such embodiment allows for lower voltage rating switches and multi-level switching thereby reducing input and output ripple and/inductance values.
[0021 ] According to another preferred implementation the converter comprises the plurality of high frequency RFC switches each connected in parallel to one of the diodes of the converter, further comprising a second high frequency RFC switch connected in parallel to the RFC inductor.
[0022] According to a further preferred implementation the converter comprises the plurality of high frequency RFC switches each connected in parallel to one of the diodes of the converter, further comprising a high frequency Cuk switch connected in parallel to the high frequency Cuk diode, a second frequency Cuk switch and a second high frequency Cuk diode connected in parallel to the second high frequency Cuk switch, whereby each the high frequency Cuk diodes the high frequency Cuk switches are connected in parallel to the series connection of the first Cuk inductor and the Cuk capacitor. As before, such embodiment allows as well for lower voltage rating switches and multi-level switching thereby reducing input and output ripple and/inductance values.
[0023] Further embodiments and advantages of the method are directly and
unambiguously derived by the person skilled in the art from the system as described before.
Brief description of drawings
[0024] These and other aspects of the invention will be apparent from and
elucidated with reference to the embodiments described hereinafter.
[0025] In the drawings: [0026] Fig. 1 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter according to a preferred embodiment of the invention,
[0027] Fig. 2 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter according to another preferred embodiment of the invention,
[0028] Fig. 3 shows in a schematically drawing a partial view of the power
converter according to Fig. 1 in another preferred embodiment of the invention,
[0029] Fig. 4 shows in a schematically drawing a partial view of the power
converter according to Fig. 1 in even another preferred embodiment of the invention, and
[0030] Fig. 5 shows in a schematically drawing a partial view of the power
converter according to Fig. 2 in another preferred embodiment of the invention.
Description of embodiments
[0031 ] Fig. 1 shows in a schematically drawing a three-phase alternating current, AC, to direct current, DC, power converter for charging an electrical vehicle 1 according to a preferred embodiment.
[0032] The converter comprises a boost power factor correction, RFC, circuit 2, a Cuk converter 3 and a transformer 4. The RFC circuit 2 is on one side connected to an AC source 5, such as an AC grid. On the other side the RFC circuit 2 is connected to the transformer 4, which is then connected to the Cuk converter 3, to which the electrical vehicle 1 is connected as DC load 6.
[0033] The three phase RFC circuit 2 comprises a low frequency diode-based converter 7, a high frequency RFC diode 8, a high frequency RFC switch 9, a RFC inductor 10 and a RFC capacitor 11. The high frequency RFC diode 8 and the high frequency RFC switch 9, which is provided as a voltage controlled FET switch, are arranged in parallel and thereby connected in parallel to an output of the diode-based converter 7 such that the anodes as well as the cathodes of the diodes of the diode-based converter 7 and of the high frequency RFC diode 8 are respectively connected together. The RFC inductor 10 has an inductance of 10 mH and the RFC capacitor 11 has a capacitance of 1000 pF are connected in series such that the RFC inductor 10 is connected to the cathodes and the RFC capacitor 11 is connected to the anodes.
[0034] Fig. 2 shows a further preferred embodiment, wherein, opposite to Fig. 1 , the high frequency RFC diode 8 and the high frequency RFC switch 9 are not connected in parallel to the output of the diode-based converter 7. Instead, each one high frequency RFC switch 9 is connected in parallel to each diode of the diode-based converter 7.
[0035] The Cuk converter 3 comprises a first Cuk inductor 12 and a Cuk capacitor
13, which are connected in series. The first Cuk inductor 12 has an inductance of 10 mH and the Cuk capacitor 13 has a capacitance of 1000 pF. The Cuk converter 12 further comprises a high frequency Cuk diode
14, which is connected in parallel to the series connection of the first Cuk inductor 12 and the Cuk capacitor 13. The anode of the high frequency Cuk diode 14 is connected, via the transformer 4, to the anode of the high frequency RFC diode 8.
[0036] The Cuk converter 3 further comprises a second Cuk inductor 15 having an inductance of 1000 pH, which is connected to the cathode of the high frequency Cuk diode 14. Such way the second Cuk inductor 15 and the anode of the high frequency Cuk diode 14 form a Cuk output 16, to which the electrical vehicle 1 is connected as DC load 6. Further, the anode of the high frequency Cuk diode 13 is connected to the negative potential of the Cuk output 16. The further embodiment of Fig. 2 shows a high frequency Cuk switch 17, which is connected in parallel to the high frequency Cuk diode 14.
[0037] The transformer 4 is connected with its primary side in parallel to the RFC capacitor 11 and with its secondary side in parallel to the Cuk capacitor 13, thereby connecting the RFC circuit 2 and the Cuk converter 3. Such way the Cuk capacitor 13 and the RFC capacitor 11 are connected, via the transformer 4, to the negative potential of the Cuk output 16. The RFC inductor 10 is connected, via the transformer 4 and the first Cuk inductor 11 and the second Cuk inductor 15 to the positive potential of the Cuk output 16.
[0038] Fig. 3 shows an enlarged respectively partial view of the RFC circuit 2 according to a further preferred embodiment. Phase inductors 18 having each an inductance of 1000 pH are provided in each current path between the AC source 5 and the diode-based converter 7. Further, a trap filter is provided comprising two sets of each three trap capacitors 19 having each a capacitance of 1000 pF and three respective trap inductors 20 having each an inductance of 1000 pH. Each three trap inductors 20 are connected star-like together and in series with each one trap capacitors 19 to one phase between the phase inductors 18 and the converter 7.
Furthermore, three phase capacitors 21 are provided each having a capacitance of 1000 pF. The phase capacitors 21 are connected star-like together and each to one phase between the phase inductors 18 and the AC source 7.
[0039] Fig. 4 shows a further embodiment of the RFC circuit 2, whereby a second high frequency RFC diode 22 and a second high frequency PFC switch 23 are provided. The high frequency PFC diode 8 and the second high frequency PFC diode 22 are connected in series and such wise in parallel to the output of the converter 7. The high frequency PFC switch 9 and the second high frequency PFC switch 23 are also connected in series and such wise in parallel to the output of the converter 7. Besides that said switches 9, 23 and diodes 8, 22 are star-like interconnected. A further high frequency PFC diode 24 is provided for receding losses
[0040] In Fig. 5 another embodiment is depicted, wherein each one high
frequency PFC switch 9 is connected in parallel to one of the diodes of the converter 7. Further, the second high frequency PFC switch 23 is connected in parallel to the PFC inductor 10. The Cuk converter 3 comprises a second high frequency Cuk switch 24 and a second high frequency Cuk diode 25. The high frequency Cuk switch 17 and the high frequency Cuk switch 24 are connected in series and such wise parallel to the series connection of the second high frequency Cuk switch 24 and the second high frequency Cuk diode 25, which are connected in parallel to the series connection of the Cuk first inductor 12 and the Cuk capacitor 13.
[0041 ] While the invention has been illustrated and described in detail in the
drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to be disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word“comprising” does not exclude other elements or steps, and the indefinite article“a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting scope.
Reference signs list
[0042] 1 electrical vehicle
2 RFC circuit
3 Cuk converter
4 transformer
5 AC source
6 DC load
7 diode-based converter
8 high frequency RFC diode
9 RFC switch
10 RFC inductor
1 1 RFC capacitor
12 first Cuk inductor
13 Cuk capacitor
14 high frequency Cuk diode
15 second Cuk inductor
16 Cuk output
17 high frequency Cuk switch
18 phase inductor
19 trap conductor
20 trap inductor
21 phase capacitor
22 second high frequency RFC diode
23 second high frequency RFC switch
24 second high frequency Cuk switch
25 second high frequency Cuk diode

Claims

Claims
1. Three-phase alternating current, AC, to direct current, DC, power converter, comprising
a boost power factor correction, RFC, circuit (2) comprising a low frequency diode-based converter (7) configured for connecting a RFC input of the converter (7) to an AC source (5), and a RFC inductor (10) and a RFC capacitor (11 ) connected in series together and in parallel to a RFC output of the converter (7), further comprising either a high frequency RFC diode (8) and a high frequency RFC switch (9) connected in parallel to the RFC output of the converter (7) or comprising a plurality of high frequency RFC switches (9) each connected in parallel to one of the diodes of the converter (7),
a Cuk converter (3) comprising a first Cuk inductor (12) and a Cuk capacitor (13) connected in series, a second Cuk inductor (15) and a high frequency Cuk diode (14) connected in parallel to the series connection and forming, via a series connection with the second Cuk inductor (15), a Cuk output (16) to which a DC load (6) can be connected, and
a transformer (4) having a primary side connected in parallel to the RFC capacitor (11 ) and a secondary side connected in parallel to the Cuk capacitor
(13).
2. Converter according to the previous claims, whereby the RFC capacitor (11 ), via the transformer (4), and the Cuk capacitor (13) are connected to the negative potential of the Cuk output (16) and the RFC inductor (10) is connected, via the transformer (4), the first Cuk inductor (12) and the second Cuk inductor (15), to the positive potential of the Cuk output (16).
3. Converter according to any of the previous claims, whereby the anode of the high frequency Cuk diode (14) is connected to the negative potential of the Cuk output (16).
4. Converter according to any of the previous claims, whereby the second Cuk inductor (15) is connected to the positive potential of the Cuk output (16) and in series with the first Cuk inductor (12). 5. Converter according to any of the previous claims, comprising a high frequency Cuk switch (17) connected in parallel to the high frequency Cuk diode (14).
6. Converter according to any of the previous claims, comprising three phase inductors (18) each arranged in a respective current path between the RFC input and the low frequency diode-based converter (7).
7. Converter according to the previous claims, comprising each three trap capacitors (19) and trap inductors (20), the trap capacitors (19) are connected together and in series with each one trap capacitors (20), whereby each one trap capacitor (19) is connected to a respective phase inductor (18) and the low frequency diode-based converter (7).
8. Converter according to any of the two previous claims, comprising three phase capacitors (21 ) connected to together and to a respective phase of the RFC input.
9. Converter according to any of the previous claims, comprising the high frequency RFC diode (8) and the high frequency PFC switch (9) connected in parallel to the PFC output of the converter (7), further comprising a second high frequency PFC diode (22) and a second high frequency PFC switch (23) connected in parallel, whereby each the PFC diodes (8, 22) the PFC switches (9, 23) are connected in parallel to the PFC output of the converter (7).
10. Converter according to any of the previous claims 1 to 8, comprising the plurality of high frequency PFC switches (9) each connected in parallel to one of the diodes of the converter (7), further comprising a second high frequency PFC switch (23) connected in parallel to the PFC inductor (10).
11. Converter according to any of the previous claims 1 to 8 or 10, comprising the plurality of high frequency PFC switches (9) each connected in parallel to one of the diodes of the converter (7), further comprising a high frequency Cuk switch (17) connected in parallel to the high frequency Cuk diode (14), a second high frequency Cuk switch (24) and a second high frequency Cuk diode (25) connected in parallel to the second frequency Cuk switch (17), whereby each the high frequency Cuk diodes (14, 25) and the high frequency Cuk switches (17, 24) are connected in parallel to the series connection of the first Cuk inductor (12) and the Cuk capacitor (13).
PCT/EP2020/057180 2019-04-02 2020-03-17 Three-phase ac to dc power converter Ceased WO2020200747A1 (en)

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