WO2023021088A1 - Inductance d'accumulation d'énergie comprenant des noyaux internes modulaires pour un convertisseur continu-continu, convertisseur continu-continu et véhicule - Google Patents

Inductance d'accumulation d'énergie comprenant des noyaux internes modulaires pour un convertisseur continu-continu, convertisseur continu-continu et véhicule Download PDF

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Publication number
WO2023021088A1
WO2023021088A1 PCT/EP2022/072956 EP2022072956W WO2023021088A1 WO 2023021088 A1 WO2023021088 A1 WO 2023021088A1 EP 2022072956 W EP2022072956 W EP 2022072956W WO 2023021088 A1 WO2023021088 A1 WO 2023021088A1
Authority
WO
WIPO (PCT)
Prior art keywords
coils
inner cores
storage choke
core
storage
Prior art date
Application number
PCT/EP2022/072956
Other languages
German (de)
English (en)
Inventor
Manuel Raimann
Pengshuai Wang
Original Assignee
Zf Friedrichshafen 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 Zf Friedrichshafen Ag filed Critical Zf Friedrichshafen Ag
Publication of WO2023021088A1 publication Critical patent/WO2023021088A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • 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
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0064—Magnetic structures combining different functions, e.g. storage, filtering or transformation
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/106—Magnetic circuits using combinations of different magnetic materials

Definitions

  • the invention relates to a storage choke for a DC-DC converter and the DC-DC converter.
  • HV batteries high-voltage batteries
  • a storage choke is present in the DC-DC converter, which is designed to temporarily store energy in the form of magnetic fields.
  • a storage choke is known, for example, from DE102017114900A1.
  • the storage choke disclosed there for a multi-phase DC-DC converter has a plurality of coils, each of which is formed by a winding of a copper wire.
  • the windings are each wound around a rod-shaped core. All of the rod-shaped cores form a first area of the storage inductor, which is formed from a first material. Furthermore, the storage choke has a second Region comprising a plurality of outer panels formed from a second material. The first material has a higher saturation magnetization and a lower magnetic permeability than the second material.
  • a storage choke is realized which is optimized with regard to its differential mode (DM) inductance and common mode (CM) inductance.
  • DM differential mode
  • CM common mode
  • the known storage choke has the disadvantage that it is complex to manufacture due to its design.
  • the storage choke according to the invention is designed to be used in a polyphase DC-DC converter for converting a DC input voltage into a DC output voltage for charging a vehicle battery or a vehicle battery arrangement in an electric vehicle or hybrid vehicle.
  • the storage choke includes several coils and a choke core.
  • the coils are magnetically coupled to one another via the inductor core.
  • the choke core is designed as a combination of two different core types.
  • the reactor core comprises a plurality of inner cores for mounting the coils and, at the same time, two outer cores between which the inner cores with the coils wound therein are arranged in the vertical direction.
  • the inner cores are of modular design, each with one or more core modules, and lined up in a horizontal direction.
  • the storage choke according to the invention can be produced easily using modular inner cores.
  • To assemble the storage choke it is possible to bring the modular inner cores with coils wound into them into the space between the two outer cores, which are preferably designed as core plates.
  • a corresponding number of inner cores can be combined in the storage choke in a simple manner in order to couple in the corresponding number of coils for the polyphase DC-DC converter.
  • the storage choke according to the invention in contrast to the known storage choke mentioned at the outset, it is not necessary to arrange a large number of cores of different designs individually in the storage choke. In this way, a storage choke is realized in which assembly is greatly simplified, without additional holding structures being required.
  • the storage choke is therefore optimized for production.
  • the inner cores each have a carrier and a preferably cylindrical shaft extending out from the carrier, around which the coils are respectively wound.
  • the carrier comprises a floor and two side borders between which the floor is arranged in such a way that an intermediate space is formed for accommodating the coil.
  • the inner cores can be used as prefabricated components whose geometry is predetermined.
  • the geometry can already be adjusted before the inner cores are installed, so that reliable optimization is ensured.
  • the various cylindrical and triangular cores must be specifically arranged individually in the storage choke in order to optimize the common-mode inductance of the storage choke, which is error-prone.
  • the inner cores each have two core modules which are arranged in such a way that their bases face one another and the associated shafts are butt-joined to one another at the front. This measure enables a simple doubling of the space provided for receiving the coils in the inner cores.
  • the coils in the inner cores are each wound along a vertical axis.
  • the inner cores are preferably arranged such that the shanks extend in the vertical direction.
  • the coils in the inner cores may each be wound along a horizontal axis.
  • the inner cores are preferably arranged such that the shanks extend in the horizontal direction, preferably coaxially. In this case, it is advantageous if adjacent coils have opposite winding directions and/or are subjected to opposite currents.
  • the inner cores are formed from a first material, with the outer cores being formed from a second material, the first material having a lower magnetic permeability and a comparatively higher saturation magnetization than the second material.
  • a higher magnetic permeability (and at the same time lower saturation magnetization) in the outer cores enables an increase in the differential mode inductance there, which reduces the reactive current in the storage choke.
  • a higher saturation magnetization and at the same time lower magnetic permeability in the inner cores, in which there is a high proportion of DC flux, enables the desired common-mode inductance to be set there in order to reduce the ripple current.
  • the invention also relates to a DC voltage converter for charging a DC voltage source, in particular a HV battery, in an electric vehicle or a hybrid vehicle.
  • a DC voltage converter for charging a DC voltage source, in particular a HV battery, in an electric vehicle or a hybrid vehicle.
  • FIG. 1 shows a schematic circuit diagram of a polyphase DC/DC converter
  • FIG. 2 shows a schematic representation of a storage choke according to an embodiment for the DC/DC converter from FIG. 1 , with a plurality of coils each wound around a separate vertical axis in an inner core comprising two core modules;
  • FIG. 3 shows a schematic representation of an inner core of the storage inductor from FIG. 2;
  • FIG. 4 shows a schematic illustration of a storage choke according to a further embodiment for the DC-DC converter from FIG. 1 , the coils each being wound around a separate vertical axis in an inner core comprising a core module;
  • FIG. 5 shows a schematic illustration of a storage choke according to a further embodiment for the DC-DC converter from FIG. 1 , with the coils each being wound around a separate horizontal axis in an inner core;
  • FIG. 6 shows a schematic representation of a storage choke according to a further embodiment for the DC-DC converter from FIG. 1 , the coils each being wound around a common horizontal axis in the storage choke.
  • Fig. 1 shows a schematic circuit diagram of a multi-phase DC-DC converter 100 for converting a DC input voltage, which is provided by a DC voltage source 107, into a DC output voltage to a rechargeable battery, in particular a high-voltage (HV) battery 109 , charge in an electric vehicle or hybrid vehicle.
  • the DC-DC converter 100 includes a storage choke 10, which is designed to temporarily store energy in the form of magnetic fluxes.
  • the storage inductor 10 has a plurality of coils 12A-C, three in this case by way of example. By applying a voltage to the windings of the coils 12A-C, a current flow and, associated therewith, a magnetic flux can be generated in the coils 12A-C.
  • the coils 12A-C are each connected between a first capacitor 101 and a half-bridge.
  • the number of half-bridges corresponds to the number of coils 12A-C.
  • Each half-bridge includes a high-side device 102A-C and a low-side device 104A-C.
  • the coils 12A-C are each connected on a side remote from the first capacitor 101 between the respective high-side device 102A-C and the low-side device 104A-C.
  • a second capacitor 106 is provided on the opposite side of the half-bridges from the first capacitor 101 .
  • a first filter 103 for eliminating interference signals in the supplied DC input voltage is connected between the input-side DC voltage source 107 and the polyphase DC voltage converter 100 .
  • a second filter 105 is connected between the HV battery 109 on the output side and the polyphase DC-DC converter 100, a second filter 105 for eliminating interference signals in the DC output voltage generated.
  • the half-bridges are switched in such a way that a voltage with the same voltage profile, but with a time offset between the coils 12A-C, is applied to the coils 12A-C.
  • a voltage with the same voltage profile but with a time offset between the coils 12A-C
  • different voltages will be present across the coils 12A-C, at least in part, while at others times the same voltage can be present across the coils 12A-C.
  • a first current also called reactive current
  • a current flowing from the HV battery 109 via the storage choke 10 and finally back to the HV battery 109 is superimposed with a current flowing from the DC voltage source 107 HV battery 109 flowing second current with time-varying shares.
  • the first current or reactive current is due to the differential mode inductance (DM inductance) of the storage inductor 10, which corresponds to the degree of increase (or the first time derivative) of the reactive current.
  • the second current is due to the common-mode inductance (CM inductance) of the storage choke 10, which results from the fact that the dimensions of the storage choke 10 cannot be increased at will. Ripple currents occur due to the CM inductance, which causes power losses. Both the reactive current and the ripple currents should be reduced as far as possible in order to optimize the voltage conversion.
  • the storage inductor 10 contains an inductor core 13 via which the coils 12A-C are magnetically coupled to one another.
  • the choke core 13 comprises a plurality of inner cores 14 for attaching the coils 12A-C and two outer cores, which are designed here by way of example as core plates 16 and between which the inner cores 14 with the coils 12A-C wound therein are arranged.
  • the outer cores 16 have a flat plate-like structure and extend in a horizontal direction.
  • the three inner cores 14 are arranged in a row between the two outer cores 16 .
  • the inner cores 14 have a modular design and can in principle each have one or more core modules, the structure of which is shown by way of example in FIG. 3 .
  • the core module has a carrier 15 and a cylindrical shaft 20 extending perpendicularly from the carrier 15 .
  • the carrier 15 comprises a floor 18 and two opposite side borders 22, between which the floor 18 is arranged.
  • the diameter of the cylindrical shaft 20 is smaller than the distance between the two side limits 22, so that a gap 24 between the cylindrical shaft 20 and the side walls 22 for receiving the respective coils 12A-C.
  • the gap 24 is exposed on a top side opposite the bottom 18 .
  • the side of the respective side limits 22 facing the cylindrical shaft 20 has a circular-arc-shaped profile.
  • the coils 12A-C are each wound around the cylindrical shaft 20 of the associated inner core 14. As shown in FIG.
  • each inner core 14 contains two core modules which are joined opposite one another in such a way that their bases 18 face one another and the associated shafts 20 are placed end to end on top of one another. In this way, the gap 24 is doubled, allowing the coils 12A-C used in this embodiment to have twice as many turns as in the single core module embodiments.
  • the inner cores 14, along with the coils 12A-C housed therein, are oriented such that the cylindrical shafts 20 extend vertically.
  • the coils 12A-C are each wound about their associated cylindrical shaft 20 about a vertical axis of their own.
  • each inner core 14 contains a single core module.
  • An inner core plate 17 is arranged between the core modules and the outer core 16 on the upper side for better guidance of the common-mode flux component.
  • the inner core plate 17 is thus a common part of the three inner cores 14.
  • the inner cores 14, together with the coils 12A-C housed there, are aligned so that the cylindrical shafts 20 extend vertically.
  • the coils 12A-C are each wound about their associated cylindrical shaft 20 about a vertical axis of their own.
  • Fig. 5 shows a storage choke 10" according to a further embodiment.
  • a plurality of inner cores 14 are arranged vertically between two outer cores 16 extending in the horizontal direction.
  • each inner core 14 likewise comprises a single core module, which is shown in Fig. 3 is shown by way of example
  • the difference between this embodiment and that in FIG The embodiment shown in Figure 4 is that the coils 12A-C are each wound about its associated cylindrical shaft 20 about a horizontal axis of its own.
  • Fig. 6 shows the storage choke 10"' according to one embodiment in a schematic representation.
  • a plurality of inner cores 14 are arranged vertically between two outer cores 16 extending in the horizontal direction.
  • each inner core 14 also comprises a single core module, which is exemplified in Fig. 3.
  • the difference between this embodiment and the embodiment shown in Fig. 5 is that the inner cores 14 are arranged between the outer cores 16 such that the various coils 12A-C about a common horizontal
  • the winding direction of the middle coil 12B is opposite to the winding directions of the other two coils 12A, C.
  • the same winding direction can be used for all three coils 12A-C, with adjacent coils 12A- C can be energized in opposite directions.
  • DM inductance In order to optimize the DM inductance and CM inductance of the storage choke 10, two different materials can be used for the two components of the choke core 13, the inner cores 14 and the outer cores 16.
  • a material with high saturation magnetization eg powder core
  • the DC flux components of the coils 12A-C compensate each other in the outer cores 16, so that there is effectively no DC flux component here.
  • a material with a low saturation magnetization can therefore be used for the outer cores 16 . This enables the use of materials with a high magnetic permeability (eg ferrite).
  • DM inductance increases with magnetic permeability.
  • the reactive current can be reduced by increasing the DM inductance.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Dc-Dc Converters (AREA)
  • Charge And Discharge Circuits For Batteries Or The Like (AREA)

Abstract

La présente invention concerne une inductance d'accumulation d'énergie (10) d'un convertisseur continu-continu polyphasé (100) qui assure la conversion d'une tension d'entrée CC en une tension de sortie CC, aux fins de chargement d'une batterie d'un véhicule électrique ou d'un véhicule hybride, l'inductance d'accumulation d'énergie (10) présentant plusieurs bobines (12A- C) et un noyau d'inductance (13) qui permet le couplage magnétique des bobines (12A-C) entre elles, le noyau d'inductance (13) comportant plusieurs noyaux internes (14) destinés au montage des bobines (12A-C), et deux noyaux externes (16) entre lesquels sont disposés les noyaux internes (14) pourvus des bobines (12Ac) enroulées dans ces derniers, les noyaux internes (14), de conception modulaire, se présentant sous la forme d'un ou de plusieurs modules de noyau et sont juxtaposés dans la direction horizontale.
PCT/EP2022/072956 2021-08-19 2022-08-17 Inductance d'accumulation d'énergie comprenant des noyaux internes modulaires pour un convertisseur continu-continu, convertisseur continu-continu et véhicule WO2023021088A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021209140.7A DE102021209140A1 (de) 2021-08-19 2021-08-19 Speicherdrossel mit modularen inneren Kernen für einen Gleichspannungswandler, Gleichspannungswandler und Fahrzeug
DE102021209140.7 2021-08-19

Publications (1)

Publication Number Publication Date
WO2023021088A1 true WO2023021088A1 (fr) 2023-02-23

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WO (1) WO2023021088A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE112007001434T5 (de) * 2006-06-29 2009-05-07 Intel Corporation, Santa Clara Konfigurierbare mehrphasige gekoppelte Magnetstruktur
US20140176291A1 (en) * 2011-08-01 2014-06-26 Sumitomo Electric Industries, Ltd. Choke coil
DE102016201258A1 (de) * 2016-01-28 2017-08-03 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Elektrischer Spannungswandler mit mehreren Speicherdrosseln
EP3211646A1 (fr) * 2016-02-26 2017-08-30 Emerson Network Power Co. Ltd. Procédé et dispositif d'enroulement de bobine d'induction
DE102017114900A1 (de) 2017-07-04 2019-01-10 Bayerische Motoren Werke Aktiengesellschaft Speicherdrossel

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7598839B1 (en) 2004-08-12 2009-10-06 Pulse Engineering, Inc. Stacked inductive device and methods of manufacturing
JP5120678B2 (ja) 2011-05-10 2013-01-16 住友電気工業株式会社 リアクトル

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE112007001434T5 (de) * 2006-06-29 2009-05-07 Intel Corporation, Santa Clara Konfigurierbare mehrphasige gekoppelte Magnetstruktur
US20140176291A1 (en) * 2011-08-01 2014-06-26 Sumitomo Electric Industries, Ltd. Choke coil
DE102016201258A1 (de) * 2016-01-28 2017-08-03 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Elektrischer Spannungswandler mit mehreren Speicherdrosseln
EP3211646A1 (fr) * 2016-02-26 2017-08-30 Emerson Network Power Co. Ltd. Procédé et dispositif d'enroulement de bobine d'induction
DE102017114900A1 (de) 2017-07-04 2019-01-10 Bayerische Motoren Werke Aktiengesellschaft Speicherdrossel

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