WO2023245864A1 - Commande de puissance adaptative pour convertisseurs de puissance isolés ca/cc ou cc/cc à deux étages - Google Patents

Commande de puissance adaptative pour convertisseurs de puissance isolés ca/cc ou cc/cc à deux étages Download PDF

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Publication number
WO2023245864A1
WO2023245864A1 PCT/CN2022/115765 CN2022115765W WO2023245864A1 WO 2023245864 A1 WO2023245864 A1 WO 2023245864A1 CN 2022115765 W CN2022115765 W CN 2022115765W WO 2023245864 A1 WO2023245864 A1 WO 2023245864A1
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WIPO (PCT)
Prior art keywords
converter
battery
voltage
link
dab
Prior art date
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PCT/CN2022/115765
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English (en)
Inventor
Yiu Pang Chan
Tin Ho Li
Kai Wing Andy Yeung
Qingchun LI
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Hong Kong Applied Science and Technology Research Institute Company Limited
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Priority claimed from US17/846,116 external-priority patent/US20220337166A1/en
Application filed by Hong Kong Applied Science and Technology Research Institute Company Limited filed Critical Hong Kong Applied Science and Technology Research Institute Company Limited
Priority to CN202280002975.0A priority Critical patent/CN115735314A/zh
Publication of WO2023245864A1 publication Critical patent/WO2023245864A1/fr

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    • 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
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/33569—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having several active switching elements
    • H02M3/33573—Full-bridge at primary side of an isolation transformer
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/02—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from ac mains by converters
    • H02J7/04—Regulation of charging current or voltage
    • H02J7/06—Regulation of charging current or voltage using discharge tubes or semiconductor devices
    • 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
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007—Plural converter units in cascade
    • 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
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • H02M1/4233—Arrangements for improving power factor of AC input using a bridge converter comprising active switches
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2207/00—Indexing scheme relating to details of circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J2207/20—Charging or discharging characterised by the power electronics converter
    • 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
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • H02M1/4216—Arrangements for improving power factor of AC input operating from a three-phase input voltage
    • 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
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/33569—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having several active switching elements
    • H02M3/33576—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having several active switching elements having at least one active switching element at the secondary side of an isolation transformer
    • H02M3/33584—Bidirectional converters

Definitions

  • Electric Vehicles are rapidly being adopted in many countries as governments subsidize EV’s and EV chargers to meet clean-energy goals. Greenhouse gas emissions such as CO2 can be dramatically reduced when EV’s are charged from electricity generated from clean energy sources such as hydroelectricity or solar.
  • the time to charge an EV can be reduced by using a higher charging power having a higher charging current or charging voltage.
  • the EV’s batteries may be charged over a wide voltage range for high-speed charging. Charging over a wide voltage range can reduce efficiencies, especially at lower battery (output) voltages where circulation currents are relatively large, resulting in high conduction losses. Also at low output voltages, charging current and power may need to be reduced to prevent over-heating of components such as semiconductors and transformers. Reducing charging current and power at low output voltages can increase charging time.
  • a two-stage power converter comprising: an Alternating Current (AC) port for connecting to an AC power grid; a Direct Current (DC) port for connecting to a battery; a battery current sensor for sensing a battery current to the battery from the DC port; a link capacitor having a DC link voltage on a link node; an AC converter, coupled to the AC port, for converting AC power from the AC power grid to the DC link voltage on the link node when connected to the link capacitor; a Dual Active Bridge (DAB) converter that receives the DC link voltage from the link capacitor, for converting the DC link voltage to a battery voltage on the DC port when charging the battery from the AC power grid; an AC controller that controls the AC converter, the AC controller generating Pulse-Width-Modulation (PWM) control signals to gates of transistors in the AC converter; a first modulator that divides a reference power constant by the battery voltage to generate a battery current reference, and that multiplies the battery current reference by a constant to generate a link reference
  • Figure 4 is a schematic of the second-stage DAB converter.
  • Figures 6A-6C show a flowchart of a variable-link adaptive power control routine to control the two-stage converter.
  • Figure 9 is a waveform diagram of PSM control signals to the primary and secondary transistors in the DAB converter.
  • Figure 13 is a plot of the two-stage converter operating in three-phase AC charging mode.
  • DAB converter 160 can operate in a reverse direction mode to discharge primary battery 132 to provide auxiliary power to VLNK or to an auxiliary DC port (not shown) .
  • PFC 150 can also operate in a reverse direction mode to provide power to the single-phase or three-phase AC grid from VLNK.
  • the P and A inputs of one-phase AC plug 154 and three-phase AC plug 156 are shorted together and applied to PFC 150.
  • the N and C inputs of one-phase AC plug 154 and three-phase AC plug 156 are shorted together and applied to PFC 150.
  • the middle B input from three-phase AC plug 156 is input to PFC 150 without any connection to one-phase AC plug 154.
  • switch SW1 shorts upper input A/P to middle input B, so that the upper and middle AC inputs to PFC 150 are shorted together by switch SW1.
  • Transistors 220, 222, 224, 226 When connected to a single-phase AC grid, switch SW1 250 is closed.
  • Transistors 220, 222, 224, 226 operate at a fast switching frequency, such as 30-60 KHz, while transistors 228, 230 operate at a slower AC-line frequency (50Hz or 60Hz) .
  • Transistors 220, 222 form a fast switching bridge with complementary PWM drive signals applied to their gates.
  • Transistors 224, 226 form another fast switching bridge with complementary PWM drive signals applied to their gates.
  • the gate of pull-up transistor 220 is driven by a PWM drive signal that is 180 degrees out of phase with the PWM drive signal applied to the gate of pull-up transistor 224.
  • the PWM drive signal applied to the gate of pull-down transistor 222 is delayed in phase by 180 degrees compared with the PWM drive signal applied to the gate of pull-down transistor 226.
  • This 180-degree phase difference causes the currents through transistors 220, 222 to be interleaved with transistors 224, 226. This interleaved operation can reduce the AC ripple current.
  • Transistors 220, 222 form one fast switching bridge for the A/P input.
  • the gates of transistors 220, 222 receive complementary PWM driving signals.
  • Transistors 224, 226 form another fast switching bridge, but this bridge is for the B input.
  • the gates of transistors 224, 226 receive complementary PWM driving signals.
  • Transistors 228, 230 form another fast switching bridge. This bridge is for the C/N input.
  • the gates of transistors 228, 230 receive complementary PWM driving signals.
  • FIG. 4 is a schematic of the second-stage DAB converter.
  • Transformer 50 isolates voltages and currents on the primary side that flow through primary windings 52 from the currents in the secondary side flowing through secondary windings 54.
  • Transformer 50 inductively couples secondary windings 54 to primary windings 52.
  • DAB converter 160 acts as a CLLLC resonant tank for a power converter, where C represents a capacitor and L represents an inductor.
  • Capacitors 28, 38 in the primary side bridge and the secondary side bridge, respectively, are connected by inductors 58, 62 in the primary and secondary sides, respectively, and the magnetic inductance of transformer 50.
  • This is a CLLLC structure with three inductors in series between the end capacitors.
  • the frequency of the PSM signals applied to the gates of transistors 20, 22, 24, 26 can be selected to achieve a desired controllable DC current gain from the DC link voltage VLNK to the DC output port VBAT, and to achieve the resonant frequency of the CLLLC tank.
  • the sensed VLNK is compared to link reference VLNK_REF by comparator 3 to generate current reference IL_REF.
  • Current reference IL_REF causes PFC digital controller 152’ to adjust the PWM control signals to PFC 150 to increase or decrease VLNK until VLNK matches VLNK_REF.
  • FIGS 6A-6C show a flowchart of a variable-link adaptive power control routine to control the two-stage converter. This routine can be implemented in the hardware and/or firmware of PFC digital controller 152 and DAB digital controller 162.
  • preset constants are obtained, step 502, such as by reading a memory device or register, or by being hardwired into the logic.
  • presets include the maximum battery current limit IBAT_MAX, minimum battery current limit IBAT_MIN, the maximum battery voltage limit VBAT_MAX, minimum battery voltage limit VBAT_MIN, the maximum DC link voltage limit VLNK_MAX, the minimum DC link voltage limit VLNK_MIN, and the target or reference power PREF.
  • the three variables are measured or sensed, step 504, including the output battery voltage VBAT and current IBAT, and the DC link voltage VLNK.
  • the battery reference current IBAT_REF is calculated as PREF/VBAT, step 506.
  • CP mode is used, step 524. CP mode usually provides faster charging than CC or CV modes.
  • the DC link reference VLNK_REF is calculated as K *IBAT_REF, step 526, where IBAT_REF was limited to IBAT_MAX for CC mode by step 522, or is PREF/VBAT for CP mode, steps 506, 524.
  • VLNK_REF is greater than the maximum link voltage limit VLNK_MAX, step 530, then VLNK_REF is reduced to VLNK_MAX, step 532, and charging uses CC mode.
  • constant-current CC mode rather than the faster-charging CP mode is used when the DC link reference voltage exceeds the maximum, steps 530, 532, or when the battery current reference exceeds the maximum, steps 510, 522. When these maximums are not exceeded, then constant power CP mode can be used for faster charging.
  • VLNK_REF is raised to the minimum VLNK_MIN, step 542. Charging can still use either CP or CC mode.
  • IBAT is compared to IBAT_REF for CP mode, or to IBAT_MAX for CC mode, or VBAT is compared to VBAT_MAX for CV mode, to adjust the duty cycle ratio and phase shift between the primary and secondary PSM control signals that are generated by DAB digital controller 162 and driven to primary and secondary transistors in DAB converter 160.
  • Steps 552 and 554 may be performed many times in parallel before looping back to step 504 when new measurements of VLNK, IBAT, or VBAT are taken. Then IBAT_REF and VLNK_REF are recalculated. The targets for IBAT, VBAT, and VLNK are then shifted based on the new measurements of IBAT, VBAT, and VLNK. Once the battery is fully charged the process can be terminated (not shown) .
  • Figure 7 shows waveforms of CC and CP charging modes using the two-stage power converter.
  • two-stage converter 120 is activated and PFC 150 rapidly drives VLNK to higher voltages as VLNK is raised from 300v at time T0 to 500v at time T1.
  • Battery current IBAT and output power to the battery rise quickly as DAB converter 160 uses the rising VLNK to drive more current and power to the battery.
  • CC mode begins at time T1 and extends to time T3.
  • the DC link voltage VLNK is kept constant during CC mode since IBAT_REF is limited and not a function of VBAT (steps 522, 506 Fig. 6A) .
  • IBAT_REF PREF/VBAT is now less than IBAT_MAX (Fig. 6A steps 506, 510, 524) , so CC mode ends and CP mode starts.
  • the output power remains constant during CP mode, but IBAT is reduced as VBAT rises with the charging battery to maintain a constant power (IBAT *VBAT) .
  • Figures 8A-8B show circuit models of the DAB converter.
  • Fig. 8A shows a First Harmonic Approximation (FHA) model of DAB converter 160.
  • Transformer 50 isolates voltages and currents on the primary side that flow through primary windings 52 from the currents in the secondary side flowing through secondary windings 54.
  • Transformer 50 inductively couples secondary windings 54 to primary windings 52.
  • Primary voltage source 61 is the voltage generated by primary transistors 20, 22 and 24, 26 in DAB converter 160.
  • the midpoint of the bridge between transistors 20, 22, node P1 is connected in series with inductor 58 and primary windings 52. This AC current through primary windings 52 then flows through capacitor 28 to the second interior node P2 of the bridge, between transistors 24, 26.
  • Secondary voltage source 63 is the voltage generated by secondary transistors 30, 32, 34, 36. Secondary voltage source 63 is connected by a loop that includes inductor 62, secondary windings 54, and capacitor 38 in series.
  • Figure 8B is a simplified model of the DAB converter.
  • Inductor 55 models transformer 50. Parameters are referred to the primary side, so the values of inductor 62 and capacitor 38 are adjusted.
  • the power transfer through DAB converter 160 can be calculated as:
  • n is the turns ratio N1/N2, where N1 is the number of turns in primary windings 52 and N2 is the number of turns in secondary windings 54.
  • M is the modulation factor
  • ⁇ p is the primary-side duty cycle and ⁇ s is the secondary-side duty cycle and ⁇ is the phase difference between the primary and secondary.
  • M is between 0 and 1. The higher the modulation factor M, the higher the output power.
  • Figure 9 is a waveform diagram of PSM control signals to the primary and secondary transistors in the DAB converter.
  • the PSM control signals to the gates of primary-side transistors 20, 22, 24, 26 are G_20, G_22, G_24, and G_26, respectively that generate primary voltage Vp.
  • the PSM control signals to the gates of secondary-side transistors 30, 32, 34, 36 are G_30, G_32, G_34, and G_36, respectively, that generate secondary voltage Vs.
  • the PSM signals to the gate of transistor 20, G_20, is delayed by ⁇ p to obtain G_24 to the gate of transistor 24.
  • G_22 is the inverse of G_20 and G_26 is the inverse of G_24.
  • the PSM signals to the gate of transistor 20, G_20, is delayed by - ⁇ to obtain G_30 to the gate of transistor 30.
  • the PSM signals to the gate of transistor 30, G_30, is delayed by ⁇ s to obtain G_34 to the gate of transistor 34.
  • G_32 is the inverse of G_30 and G_36 is the inverse of G_34.
  • FIG. 10 ⁇ is a diagram of the first-stage PFC digital controller when configured for a charging mode with totem-pole power-factor correction.
  • Charging mode in this example is when primary battery 132 is being charged from AC.
  • DAB digital controller 162 uses DC-link adaptive control to reduce the circulating current in transistors in DAB 160 and to improve efficiency compared to having a fixed DC link voltage.
  • PFC digital controller 152 obtains the reference battery current IBAT_REF of primary battery 132 from minimizer 331 in DAB digital controller 162 and uses the reference battery current IBAT_REF to adjust the PWM control signals.
  • Reference battery current IBAT_REF is multiplied by the constant K by multiplier 270 and input to minimizer 281 that passes the product IBAT_REF *K through as VLNK_REF when smaller than the maximum link voltage VLNK_MAX.
  • VLNK_REF The minimum from minimizer 281, VLNK_REF, is a reference battery voltage for the whole control loop. This reference battery voltage is compared to the peak AC voltage, VAC-PEAK, and the maximum of VLNK_REF and VAC-PEAK is selected by maximum selector 280.
  • DC link voltage VLNK is sampled by voltage sampler 258 to generate VLNK-S, which is subtracted by adder 282 from the maximum voltage selected by maximum selector 280.
  • Proportional-Integrator (PI) 284 integrates the sum from adder 282, which is then multiplied in multiplier 286 by the reciprocal of the square of the Root-Mean-Square (RMS) AC voltage, and then multiplied in multiplier 288 by the current AC voltage, VAC, to generate current reference IL-REF.
  • the current flowing through the A and B AC lines are sensed by hall sensor 252 as currents IA and IB, respectively.
  • the AC voltages of the A and C lines are sensed by voltage sensor 256 as VAC-P and VAC-N, respectively.
  • Polarity detector and calculator 251 rectifies VAC and calculates VRMS and also generates a polarity signal that causes selector 254 to select IA or IB to generate LA-FB and LB-FB.
  • This LA-FB current from selector 254 is subtracted from the reference current IL-REF by adder 274, then integrated by Proportional-Integrator (PI) 264 and multiplied by VAC/ (VLNK-S) by multiplier 272 to control the pulse width or duty cycle of the control signals to the gates of pull-up transistor 220 and pull-down transistor 222 that are generated by PWM controller 260.
  • PI Proportional-Integrator
  • the LB-FB current from selector 254 is subtracted from the reference current IL-REF by adder 278, then integrated by Proportional-Integrator (PI) 266 and multiplied by VAC/ (VLNK-S) by multiplier 276 to control the pulse width of the control signals to the gates of pull-up transistor 224 and pull-down transistor 226 that are generated by PWM controller 262.
  • PI Proportional-Integrator
  • the PWM control signals to the gates of pull-up transistor 228 and pull-down transistor 230 are generated by another PWM controller (not shown) to have a switching frequency equal to the AC input frequency, such as 50 Hz or 60 Hz for single-phase AC operation. For three-phase AC operation, space-vector PWM control signals are generated.
  • Figure 11 shows the DAB digital controller configured for a charging mode.
  • all three modes Constant-Voltage (CV) , Constant-Current (CC) , and Constant-Power (CP) , are considered by the control loop in DAB digital controller 162.
  • the battery voltage VBAT sensed by voltage sensor 320 as VBAT-S while the battery current IBAT is sensed by Hall sensor 314 as IBAT-S.
  • the reference power PREF in register 308 is divided by the sensed battery voltage VBAT-Sby divider 312 to get the CP mode current limit that is applied to the upper input of minimizer 331.
  • PI Proportional-Integrator
  • Minimum selector 330 selects the minimum reference from among the CP/CC mode (upper input from PI 302) and the CV mode (lower input from PI 334) .
  • all three modes, Constant-Voltage (CV) , Constant- Current (CC) , and Constant-Power (CP) are considered by the control loop in DAB digital controller 162.
  • CV mode is triggered when the phase shift reference for CV mode, generated by PI 334, is smaller than the phase shift reference for CP/CC mode, generated by PI 302. Then minimum selector 330 selects the reference for CV mode.
  • the output of minimum selector 330 is theta ⁇ that is limited by phase shift limiter 336.
  • the duty cycle is calculated by duty cycle calculator while the dead time is calculated by dead time calculator 338.
  • Dead-time calculator 338 calculates the dead time when the pull-up and pull-down transistors are both off during switching to prevent current surges.
  • the PSM control signals to the gates of primary-side transistors 20, 22, 24, 26 are generated by phase-shifted PSM controller 340 based on the control loop calculation of phase shift ⁇ .
  • the phase shift along with the duty ratio can be modulated for phase shift modulation control.
  • the control signals to the gates of secondary-side transistors 30, 32, 34, 36 are also generated by phase-shifted PSM controller 340.
  • Figure 12 is a plot of the two-stage converter operating in single-phase AC charging mode.
  • the AC input has a sine wave for the AC voltage and the AC current measured on input A/P.
  • the DC link voltage fluctuates with the AC input, but the fluctuations are very small. For example, when the AC input voltage is +/-300 volts, the peak AC current is 20 A, and the DC link voltage is 380 volts +/-12 volts. So the fluctuation on the DC link voltage is 24/380, or about 6%. Total Harmonic Distortion (THD) is low.
  • the AC current is in-phase with the AC voltage and operating with totem pole power factor correction control.
  • Figure 13 is a plot of the two-stage converter operating in three-phase AC charging mode.
  • the AC input has three sine waves, for the A, B, and C AC inputs. These sine waves are separated in phase by 120 degrees.
  • the AC current is in-phase with the AC voltage for each of the 3 inputs.
  • Each sine wave alternates in voltage from –300 volts to + 300 volts, with the current alternating from –20 A to +20 A.
  • PFC 150 is operating with space vector PWM control with a low THD.
  • the input AC current is almost in phase with the input AC voltage.
  • the DC link voltage fluctuates with the three AC inputs, but the fluctuations are very small. For example, when the AC input voltage is +/-300 volts, the DC link voltage fluctuates from about 649.9 volts to 650.2 volts. So the fluctuation or ripple on the DC link voltage is 0.3/650, or about 0.05%.
  • pull-up transistor 220 and pull-down transistor 222 can both be n-channel transistors, or pull-up transistor 220 could be a p-channel transistor and pull-down transistor 222 could be an n-channel transistor, with the gate voltages inverted to account for the inherent p-channel inversion of logic.
  • Other transistors could likewise all be n-channel or could have p-channel pull-ups.
  • the first stage can be a buck converter, boost converter, buck-boost converter or other unidirectional or bidirectional DC-DC converters.
  • the second stage can be a CLLLC DAB converter, LCL DAB converter or other immittance-based DAB converters.
  • the first stage and second stage are connected together by a DC link voltage VLNK that is generated on a link capacitor so that the first stage can generate a variable VLNK based on a function of the reference output current/power of the second stage.
  • DAB digital controller 162 may generate the PSM control signals with a fixed switching frequency equal to a resonant frequency of DAB 160 for maximum efficiency.
  • the constant K that is multiplied by multiplier 270 can be calculated to be within 10% (0.9) as
  • a constant switching frequency may be used with phase shift modulation to regulate the output power or current.
  • the phase shift can be changed to provide reverse operation, such as EV to grid.
  • the modulation factor M can be kept high to reduce reactive power losses in DAB converter 160.
  • Switches could be power relays or could be transistor switches or transmission gates.
  • the switching frequency of DAB converter 160 may be fixed at the resonant frequency. Then the DC link voltage is variable and non-regulated, and PFC 150 is used to regulate the AC output current or voltage.
  • the two-stage converter may be onboard an EV
  • the two-stage converter could be located at the home, can be an EV charger station, or can be a portable EV charger, without being onboard an EV.
  • Two-stage converter 120 could be divided into a portion that is on-board the EV and another portion that is at the home or charger station.
  • Two-stage converter 120 could be used for purposes other than EV’s , such as for backup power systems, powering industrial or medical equipment.
  • Two-stage converter 120 can also be a renewable energy storage system.
  • the battery can be discharged to provide energy to the grid, while during low demand times, the battery can be charged from energy from the grid or from a solar panel. Thus is can provide peak power leveling for the power grid’s stability and security.
  • the DC link voltage can rise when the battery voltage falls over a limited range and can be relatively constant when outside of that operating range.
  • the switching frequency can be considered to be equal to the resonant frequency when they are within a desired range, such as within an order of magnitude, or within 10%. Efficiency is highest when the switching frequency is exactly equal to the resonant frequency, but variances in inductances and capacitances and other circuit features and layouts can make exact matching unreasonable or unrealistic, so matching within a range such as an order of magnitude can be considered a match.
  • More complex logic and control trees could be added to the control loops, such as to add disabling transistors to disable operation, such as for power-down modes.
  • Filters could be added to various nodes, such as by adding capacitors, resistors, inductors, or networks of resistors, capacitors and inductors. Leaker resistors could be added. Parasitic capacitances and resistances may be present. Hysteresis could be added for more complex waveform shaping. Buffers could be added between stages, or more stages or dummy stages could be added.
  • Auxiliary windings could be present in some transformer embodiments, and some embodiments may have more than 3 sets of windings, or in different polarities and configurations.
  • Calculations such as by a divider, minimum selectors and minimizers, multiplier, etc. could be performed by hardware units, either specific units or general-purpose units that can be programmed by firmware or software. Comparisons could be performed in the analog domain by comparators, op amps, etc., or could be digital comparators that compare digital values that could be generated by an Analog-to-Digital Converter (ADC) from analog voltages and currents. Calculational logic could be shared or reused or could be dedicated.
  • ADC Analog-to-Digital Converter
  • PWM or PSM control signals have been described as having 180-degree phase separations. It is understood that these are ideal phase values, and that actual phases may vary somewhat, such as +/-5%, 10%, etc., and still be considered to have 180-degree phase separation.
  • the background of the invention section may contain background information about the problem or environment of the invention rather than describe prior art by others. Thus inclusion of material in the background section is not an admission of prior art by the Applicant.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Rectifiers (AREA)

Abstract

L'invention concerne un convertisseur de puissance comprenant un convertisseur de facteur de puissance (PFC) et un convertisseur à double pont actif (DAB) à deux étages connectés ensemble par une tension de liaison CC. Le convertisseur DAB délivre une tension de batterie avec un courant de batterie. Un dispositif de commande de convertisseur PFC divise une puissance de référence constante par la tension de batterie pour obtenir une référence de courant de batterie qui est multipliée par une constante et comparée à la tension de liaison CC pour ajuster des signaux de commande de modulation de largeur d'impulsion (PWM) au dispositif PFC. La constante de puissance de référence est comparée au courant de batterie pendant un mode de puissance constante pour entraîner la modulation par un contrôleur de convertisseur DAB du rapport cyclique et de la différence de phase entre des signaux de commande de modulation PWM côté primaire et côté secondaire au convertisseur DAB. Le rapport cyclique de convertisseur DAB et la différence de phase sont modulés par comparaison du courant de batterie à une limite de courant de batterie pendant un mode à courant constant et par comparaison de la tension de batterie à une limite de tension de batterie pendant un mode à tension constante.
PCT/CN2022/115765 2022-06-22 2022-08-30 Commande de puissance adaptative pour convertisseurs de puissance isolés ca/cc ou cc/cc à deux étages WO2023245864A1 (fr)

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US17/846,116 2022-06-22
US17/846,116 US20220337166A1 (en) 2019-09-05 2022-06-22 Adaptive Power Control for Two-Stage AC/DC or DC/DC Isolated Power Converters

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US20180076723A1 (en) * 2016-09-15 2018-03-15 Virginia Tech Intellectual Properties, Inc. Variable dc link converter and transformer for wide output voltage range applications
CN107994777A (zh) * 2017-12-10 2018-05-04 太原理工大学 一种clllc型双向dc-dc变换器变频控制方法
CN109361318A (zh) * 2018-09-19 2019-02-19 上海交通大学 基于dab的单级隔离型pfc变换器直接电流控制系统及控制方法
CN109980761A (zh) * 2019-04-03 2019-07-05 湘潭大学 双向高频链ac-dc矩阵变换器及其控制方法
US20210313870A1 (en) * 2018-09-03 2021-10-07 Mitsubishi Electric Corporation Power conversion device

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180076723A1 (en) * 2016-09-15 2018-03-15 Virginia Tech Intellectual Properties, Inc. Variable dc link converter and transformer for wide output voltage range applications
CN107994777A (zh) * 2017-12-10 2018-05-04 太原理工大学 一种clllc型双向dc-dc变换器变频控制方法
US20210313870A1 (en) * 2018-09-03 2021-10-07 Mitsubishi Electric Corporation Power conversion device
CN109361318A (zh) * 2018-09-19 2019-02-19 上海交通大学 基于dab的单级隔离型pfc变换器直接电流控制系统及控制方法
CN109980761A (zh) * 2019-04-03 2019-07-05 湘潭大学 双向高频链ac-dc矩阵变换器及其控制方法

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