Systems and methods for a variable frequency multiplier power converter
09819272 · 2017-11-14
Assignee
Inventors
- David J. Perreault (Andover, MA)
- Khurram K. Afridi (Boulder, CO, US)
- Samantha J. Gunter (Cambridge, MA, US)
Cpc classification
H02M3/07
ELECTRICITY
H02M3/33507
ELECTRICITY
H02M1/44
ELECTRICITY
H02M1/0058
ELECTRICITY
H02M3/33523
ELECTRICITY
H02M1/0077
ELECTRICITY
Y02B70/10
GENERAL 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
International classification
H02M1/44
ELECTRICITY
H02M1/42
ELECTRICITY
Abstract
A power converter for converting DC power to DC power includes an inverter stage having two or more switched inverters configured to receive DC power from a source and produce a switched AC output power signal. A transformation stage is coupled to receive the switched output power signal from the inverter stage, shape the output power signal, and produce a shaped power signal. A rectifier stage having two or more switched inverters coupled to receive the shaped power signal and convert the shaped power signal to a DC output power signal is included. A controller circuit is coupled to operate the power converter in a variable frequency multiplier mode where at least one of the switched inverters is switched at a frequency or duty cycle that results in an output signal having a frequency that is a harmonic of the fundamental frequency being generated by the power converter.
Claims
1. A power converter comprising: an inverter stage having a plurality of switched inverters configured to receive receive a power input and produce an AC voltage based on the power input wherein the plurality of switched inverters comprises a first switched inverter and a second switched inverter; a transformation stage coupled to receive the AC voltage; a rectifier coupled to receive a signal from the transformation stage; and a controller configured to control switching of the plurality of switched inverters and configured to change a magnitude of the AC voltage by varying the switching of the plurality of switched inverters by varying a switching frequency and a duty ratio of the plurality of switched inverters, wherein the controller is configured to reduce the magnitude of the AC voltage by a factor of two by reducing the switching frequency by a factor of two and varying the duty ratio of the plurality of switched inverters, and wherein the AC voltage is reduced by a factor of two at least in part by controlling the first switched inverter to have a duty ratio of 0.25 and controlling the second switched inverter to have a duty ratio of 0.75, and switching the first switched inverter and the second switched inverter in-phase with one another.
2. The power converter of claim 1, wherein the controller is configured to vary the switching of the plurality of switched inverters based on the power input.
3. The power converter of claim 1, wherein the power converter comprises an LLC converter.
4. The power converter of claim 1, wherein the controller is configured to vary a switching frequency of the plurality of switched inverters by an integer multiple.
5. The power converter of claim 1, wherein a frequency of the AC voltage is a harmonic of the switching frequency of the plurality of switched inverters.
6. The power converter of claim 1, wherein: the first and second switched inverters of the plurality of switched inverters are stacked in series, the first switched inverter comprising a first plurality of field effect transistors, the second switched inverter comprising a second plurality of field effect transistors; and in response to a signal provided thereto from said transformation stage, said rectifier produces a DC output to a power computing device.
7. The power converter of claim 1 wherein said controller circuit is further configured to drive said rectifier stage in a variable frequency multiplier mode.
8. The power converter of claim 1 wherein: said first inverter is provided as a first half-bridge inverter and said second inverter is provided as a second half-bridge inverter; and said controller circuit is further configured to drive said inverter stage such that: said first and second half-bridge inverters are operated at a fundamental frequency that is half that of the desired output (TA=2T.sub.0); the first half-bridge inverter is controlled to have a duty ratio of 0.25 and the second half-bridge inverter is controlled to have a duty ratio of 0.75 (D1=0.25; D2=0.75); and the delay between the first and second half-bridge inverter is zero (i.e. Δt=0) such that said power converter operates in a frequency multiplier double mode of operation.
9. A method of operating a power converter, the power converter including an inverter stage having a plurality of switched inverters configured to receive a power input and produce an AC voltage based on the power input, the plurality of switched inverters comprising a first switched inverter and a second switched inverter stacked in series, the first switched inverter comprising a first plurality of field effect transistors, the second switched inverter comprising a second plurality of field effect transistors, a transformation stage coupled to receive the AC voltage, and a rectifier coupled to receive a signal from the transformation stage and produce a DC output to power a computing device, the method comprising: controlling switching of the plurality of switched inverters by varying a switching frequency and a duty ratio of the plurality of switched inverters; and changing a magnitude of the AC voltage by varying the switching of the plurality of switched inverters, the changing of the magnitude comprising reducing the magnitude of the AC voltage by a factor of two by reducing the switching frequency by a factor of two and varying the duty ratio of the plurality of switched inverters, and wherein the AC voltage is reduced by a factor of two at least in part by controlling the first switched inverter to have a duty ratio of 0.25 and controlling the second switched inverter to have a duty ratio of 0.75, and switching the first switched inverter and the second switched inverter in-phase with one another.
10. A power converter comprising: an inverter stage having a plurality of switched inverters configured to receive receive a power input and produce an AC voltage based on the power input, the plurality of switched inverters comprising a first switched inverter and a second switched inverter stacked in series, the first switched inverter comprising a first plurality of field effect transistors, the second switched inverter comprising a second plurality of field effect transistors; a transformation stage coupled to receive the AC voltage; a rectifier coupled to receive a signal from the transformation stage and produce a DC output to power a computing device; and a controller configured to control switching of the plurality of switched inverters and configured to change a magnitude of the AC voltage by varying the switching of the plurality of switched inverters by varying a switching frequency and a duty ratio of the plurality of switched inverters, wherein the controller is configured to reduce the magnitude of the AC voltage by a factor of two by reducing the switching frequency by a factor of two and varying the duty ratio of the plurality of switched inverters, and wherein the AC voltage is reduced by a factor of two at least in part by controlling the first switched inverter to have a duty ratio of 0.25 and controlling the second switched inverter to have a duty ratio of 0.75, and switching the first switched inverter and the second switched inverter in-phase with one another.
11. The power converter of claim 10, wherein the power converter comprises a series-resonant converter or a parallel-resonant converter.
12. The power converter of claim 11, wherein a frequency of the AC voltage is a harmonic of the switching frequency of the plurality of switched inverters.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The foregoing features may be more fully understood from the following description of the drawings. The drawings aid in explaining and understanding the disclosed technology. Since it is often impractical or impossible to illustrate and describe every possible embodiment, the provided figures depict one or more exemplary embodiments. Accordingly, the figures are not intended to, and should not be construed as, limiting the scope of the concepts, systems, circuits and techniques described here. Like numbers in the figures denote like elements.
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DETAILED DESCRIPTION
(16) Before describing VFX power converter concepts, systems and techniques, some introductory concepts and terminology are explained. Described herein in relation to the figures are concepts, systems and techniques for providing a variable frequency multiplier (“VFX”) power converter (also sometimes referred to herein as a “power converter” or more simply a “converter”) having an efficiency which is relatively high compared with the efficiency of prior art power converters. As used herein the term “electrical grid” (or more simply, “grid”) refers to an interconnected network for delivering electricity from suppliers to consumers and should not be taken to imply any particular physical layout or breadth. Thus, as used herein, the term “grid” may refer to an entire continent's electrical network, a regional transmission network or may be used to describe a subnetwork such as a local utility's transmission grid or distribution grid.
(17) Referring now to
(18) In one embodiment, inverter stage 102 receives a DC input signal 104 at an input thereof and provides an intermediate AC output signal 106 at an output thereof. Transformation stage 108 receives AC output signal 106 at an input thereof and transforms or operates on AC output signal 106 in one or more ways including, but not limited to: providing voltage transformation, electrical isolation, and waveform shaping, etc. to provide an AC output signal 110 at an output thereof. Rectifier stage 112, receives AC output signal 110 at an input thereof and converts AC output signal 110 into a DC output signal 114 appropriate for use in a variety of manners including, but not limited to providing power to electronic devices such as servers within a data center or to other DC loads.
(19) Coupled to inverter stage 102 and/or to rectifier stage 112 is a controller circuit 116. Controller circuit 116 is configured to control the switching operation of inverter stage 102 and/or rectifier stage 112. As will be discussed below, inverter stage 102 includes one or more switches cooperatively operable to convert DC input signal 104 into an AC output signal 106. Similarly, rectifier stage 112 includes one or more switches cooperatively operable to convert AC signal 110 back into a DC output signal 114. Controller circuit 116 is coupled to control the operation and timing of these switches.
(20) Controller circuit 116 is capable of controlling inverter stage 102 and/or rectifier stage 112 at various frequencies, depending upon the power or voltage of input signal 104 and the desired output power or voltage of output signal 114. Although a DC/DC converter is shown, the converter 100 can also function as an AC/DC, DC/AC or AC/AC converter, by the addition of a rectification and/or inversion stage at the input and/or the output port.
(21) Converter 100 is also capable of operating over a wide operating range in voltage (e.g., large conversion ratios—such as large step-down transformation, and large variations in required conversion ratio) and wide operating range in power. In particular, by changing the operating frequency, duty cycle, and/or other timing of inverter 102 and/or rectifier 112, controller 116 can change the operating mode of converter 100 to increase the efficiency of converter 100 when converter 100 is operating with different input voltages or power, output voltages or power, etc. In effect, converter 100 can change operating mode to “shift gears” of the controller 100 to compensate for different input and output voltages to increase the range for which high-efficiency operation of converter 100 can be maintained.
(22) In one exemplary embodiment, controller 116 can change the operating mode of converter 100 without altering the dominant frequency at which power is transferred through the transformation stage 108. In other words, controller 116 may operate inverter 104 at a harmonic frequency that is an integer multiple of a fundamental frequency of the inverter stage 104 and/or operate the transformation stage 108 at a frequency that is a harmonic frequency that is an integer multiple of a fundamental frequency of the transformation state 108 or the rectifier stage 112. By changing the frequency of operation of rectifier stage 112, converter 100 can also provide a natural step-down voltage conversion through rectifier stage 112 in applications where this is desirable, which may reduce the burden and power loss associated with the transformation stage 108.
(23) Referring now to
(24) Inverter circuits 200 and 202 and rectifier circuits 204 and 206 include internal switching elements (or more simply “switches”) having control terminals, as will be discussed below. In some exemplary embodiments, these switches are implemented by one or more field effect transistors (FETs). Controller 116 may be coupled to the switching element control terminals (e.g. gates of the FETs) in order to control operation of the switches. In embodiments, controller 116 can control the switching operation of inverter 200 independently of the switching operation of inverter 202, and control the switching operation of rectifier 204 independently of the switching operation of rectifier 206. For example, controller 116 can operate inverter 200 at one frequency or duty cycle, and simultaneously operate inverter 202 at another frequency and/or duty cycle. Of course, controller 116 can operate inverters 200 and 202 at the same frequency and duty cycle, if desired. The same concept applies to rectifier 204 and 206—controller 116 can operate rectifier 204 and 206 independently of one another.
(25) Transformation stage 108 includes a so-called Impedance Control Network (“ICN”). However, other types of transformation stages can also be used including resonant conversion networks and/or the inductive transformer network such as used in a dual-active bridge system. Transformation stage 108 operates to shape the operating waveforms to maintain simultaneous zero voltage switching (ZVS) and near zero current switching (ZCS) of the transistors across operating range, to reduce (and ideally minimize) stress and switching loss, and enabling converter 100b to be implemented having both a high efficiency and power density. While the exemplary converter 100b is shown as incorporating an impedance control network, it will also be appreciated that the variable frequency multiplying controller 116, inverter stage 102, and/or rectifier stage 112 can be included in other converter systems, including series-resonant converters, parallel-resonant converters, series/parallel resonant converters, LLC converters and other resonant and non-resonant power converters, including dual-active bridge converters and related variants (such as using more complicated inverter or rectifier structures), double-ended forward converters, etc.
(26) Although inverter circuits 200 and 202 are shown coupled in a parallel configuration in the exemplary embodiment of
(27) As noted above, converters 100 and 100b employ frequency multiplier operating modes of the inverter stage and/or rectifier stage to maintain high-efficiency performance across a wide operating range of input power or voltage, and output power or voltage.
(28) In one exemplary embodiment, converters 100 and 100b employ an additional operating mode of the inverter and/or rectifier to increase operating range, such as for reduced output voltage and/or output power conditions or for high input-voltage conditions. In this context, frequency multiplication can be used to extend the efficient operating range of a converter and improve its performance (e.g., for low powers and low output voltages).
(29) To illustrate this concept,
(30) In operation, the input voltage V.sub.in is split in two, with each half bridge ideally provided having a voltage level V.sub.DC corresponding to 0.5.Math.V.sub.IN,TOT (i.e. V.sub.DC=0.5.Math.V.sub.IN,TOT). It should be noted that a conventional full bridge inverter comprising two half-bridges with paralleled inputs could also be used.) By controlling the fundamental switching period of the constituent half-bridge inverters, in addition to the duty ratios D.sub.1 and D.sub.2 of the bottom half 320 and top half 322 bridge inverters, and the time delay Δt between them, the inverter circuit 300 can produce output waveforms v.sub.o(t) that have desirable characteristics at a frequency f.sub.0 (operating period T.sub.0=1/f.sub.0) needed to drive the load network (not shown). The inverter system can be controlled to synthesize an output frequency f.sub.0 that is a multiple (i.e. a harmonic) of the fundamental inverter switching frequency f.sub.A=1/T.sub.A (i.e., such that the stacked-bridge inverter is operated as a frequency multiplier). Moreover, through proper selection of operating points, one can vary the multiplier ratio, providing so-called “gear shifts” in operation, while preserving soft switching and other desired operating characteristics.
(31) Referring now to
(32) If one of the constituent half-bridges is operated with duty ratio D.sub.1 and period T.sub.A with an even operating waveform, as illustrated in
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(34) Referring now to
(35) Operating the inverters at the desired output frequency (e.g. T.sub.A=T.sub.0), with a delay of half a cycle Δt=0.5, T.sub.A between the half bridges and with identical duty ratios D.sub.1=D.sub.2=0.5 results in an output waveform as shown in
(36) Referring now to
(37) Referring now to
(38) The examples above are extensible when applied in an impedance control network (“ICN”) converter system. The ICN can be used to reduce switch count and/or achieve additional multiplier modes of operation.
(39) Referring to
(40) In fundamental mode, the half-bridge inverters 902 and 904 operate at the desired output frequency f.sub.0 under phase-shift control at D=0.5, as previously described. In multiplier mode, controller 116 operates the half-bridge inverters at half that of the desired output frequency (with D.sub.1=0.25 and D.sub.2=0.75, which maximizes the second harmonic component). In this case, partial cancellation of the fundamental output components of the half-bridge inverters is achieved (due to the ICN control requirements). This is augmented by the filtering properties of the ICN network 906 to attenuate the undesired fundamental component. In operation, the frequency component of the output at f.sub.0/2 has negligible impact over the operating range of the system in multiplier mode. Thus, by changing the frequency and/or duty cycle of the inverters, the circuit can operate at lower output power, switching loss, and conduction loss over a wide range of inputs voltages and powers and output voltages and powers.
(41) It is also possible to realize further multiplier operating modes. For example, in addition to fundamental and doubler mode, the converter 700 shown in
(42) It is also possible to control the output power of the converter by controlling the phase shift between the inverters, instead of or in addition to controlling the frequency and duty cycle and/or bursting the converter on and off. In this case, the lossless combiner (e.g. transformation stage 108 in
(43) The availability of additional operating modes with a VFX inverter stage enables efficient operation over wide input and output power ranges. Furthermore, because lower synthesized drive voltages can be used in multiplier mode, this technique can be applied to efficiently operate across increased input voltage ranges or output voltage ranges.
(44) Referring to
(45) For example, the converter circuit 1000 in
(46) Similarly, the controller can operate inverter 1010 and inverter 1012 of the rectifier stage at the fundamental frequency and duty cycle or at a multiple of the fundamental frequency and duty cycle, as described above. The controller can also operate inverters 1006 and 1008 in the same mode or in different modes from each other, as described above.
(47) In an embodiment, the rectifier stage may be implemented as a half-bridge rectifier, such as that shown in
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(49) In some exemplary embodiments, the mode of operation of the inverter structure and rectifier structure can provide a natural voltage or power step-down. As noted above with regard to
(50) In embodiments, the controller can operate one or more of the inverters in the inverter stage in variable frequency mode and/or one or more of the inverters in the rectifier stage in variable frequency mode. By doing so, the converter circuit can achieve high efficiency over a wide range of input voltages and power and output voltages and power, depending upon the desired application.
(51) Having described preferred embodiments, which serve to illustrate various concepts, structures and techniques which are the subject of this patent, it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts, structures and techniques may be used. Accordingly, it is submitted that that scope of the patent should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the following claims. All references cited herein are hereby incorporated herein by reference in their entirety.