ACTIVE FILTER FOR SINGLE PHASE CHARGING USING A SWITCH-MODE CONVERTER

Abstract

A converter for electrical connection to a three-phase electrical grid and a single-phase electrical grid is provided. The converter includes three DAB modules, each for converting a respective alternating current of a three-phase electrical grid. When connected to a single-phase electrical grid, the third DAB module is bi-directional such that it is operable to filter the power output of the first and second DAB modules. The converter further includes a filter capacitor in electrical communication with the third DAB module through a relay, wherein the relay is responsive to a controller to couple the third DAB module to the filter capacitor when the single-phase electrical grid is detected and to couple the third DAB module to a grid rectifier when the three-phase electrical grid is detected.

Claims

1. An on-board charger for a vehicle comprising: a first switch-mode converter being operable to convert a first rectified voltage into a first DC component; a second switch-mode converter being operable to convert a second rectified voltage into a second DC component; a third switch-mode converter being operable to convert a third rectified voltage into a third DC component, the third switch-mode converter being bidirectional such that the third switch-mode converter is operable as an active filter to remove harmonics from a DC output of the first and second switch-mode converters when coupled to a single-phase electrical grid; and a filter capacitor selectively coupled to an input stage of the third switch-mode converter, wherein the filter capacitor draws power from the DC output through the third switch-mode converter if the DC output is greater than a power reference and supplies power to the DC output through the third switch-mode converter if the DC output is less than the power reference.

2. The on-board charger of claim 1 wherein each of the first, second, and third switch-mode converters includes a dual-active-bridge topology.

3. The on-board charger of claim 1 further including a first rectifier, a second rectifier, and a third rectifier electrically coupled in series with the first switch-mode converter, the second switch-mode converter, and the third switch-mode converter, respectively.

4. The on-board charger of claim 2 wherein the first rectifier, the second rectifier, and the third rectifier each include a full bridge topology.

5. The on-board charger of claim 2 further including a relay to alternatively couple the input stage of the third switch-mode converter to the third rectifier and the filter capacitor.

6. The on-board charger of claim 5 further including a controller to detect a single-phase AC input voltage and a three-phase AC input voltage and to control operation of the relay.

7. The on-board charger of claim 6 wherein each of the first, second, and third switch-mode converters provide unity power factor when coupled to the three-phase AC input voltage.

8. The on-board charger of claim 6 wherein the third switch-mode converter is operated 180° out of phase relative to the first and second switch-mode converters when the single-phase AC input voltage is detected by the controller.

9. The on-board charger of claim 6 further including a voltage sensor across the filter capacitor, the voltage sensor being coupled to the controller.

10. The on-board charger of claim 1 wherein the power reference is selected such that the third switch-mode converter destructively interferes with the harmonics of the DC output.

11. A method for converting an AC input voltage into a DC output voltage comprising: providing an on-board charger including a first rectifier, a second rectifier, and a third rectifier electrically coupled in series with a first switch-mode converter, a second switch-mode converter, and a third switch-mode converter, respectively; in response to a three-phase AC input being detected at the on-board charger, operating the first rectifier and the first switch-mode converter to convert a first phase of the AC input into a first DC component, operating the second rectifier and the second switch-mode converter to convert a second phase of the AC input into a second DC component, and operating the third rectifier and the third switch-mode converter to convert a third phase of the AC input into a third DC component; and in response to a single-phase AC input being detected at the on-board charger, filtering a DC output of at least one of the first and second switch-mode converters through the third switch-mode converter to reduce harmonics in the DC output, wherein filtering the DC output includes de-coupling the third switch-mode converter from the third rectifier and coupling an input stage of the third switch-mode converter to a filter capacitor, such that the filter capacitor draws power from the DC output if the DC output is greater than a power reference and supplies power to the DC output if the DC output is less than the power reference.

12. The method of claim 11 wherein the first rectifier, the second rectifier, and the third rectifier each include a full bridge topology.

13. The method of claim 11 wherein the first switch-mode converter, the second switch-mode converter, and the third switch-mode converter each include a dual-active-bridge topology.

14. The method of claim 11 wherein the filter capacitor includes a capacitor bank, the capacitor bank being coupled to the third switch-mode converter through a relay.

15. The method of claim 11 further including coupling the DC output of the on-board charger to a vehicle battery.

16. The method of claim 11 further including coupling the filter capacitor to a DC output of the on-board charger through first and second switches when a three-phase AC input is detected to reduce current ripple in the DC output of the on-board charger.

17. The method of claim 16 further including decoupling the filter capacitor from the DC output of the on-board charger through the first and second switches when a single-phase AC input is detected.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a circuit diagram of a three-phase/single-phase, single stage on-board charger for a vehicle battery.

[0014] FIG. 2 is a circuit diagram of a first alternative embodiment of the on-board charger of FIG. 1.

[0015] FIG. 3 is a circuit diagram of a second alternative embodiment of the on-board charger of FIG. 1.

[0016] FIG. 4 includes three embodiments of a relay for disconnecting the electrical grid and connecting the filter capacitor.

[0017] FIG. 5 includes six embodiments of relay placement to switch electrical connection to the DAB module between the electrical grid and the filter capacitor.

[0018] FIG. 6 is a circuit diagram of an on-board charger including a filter capacitor between a full bridge rectifier and a full-bridge DAB primary.

[0019] FIG. 7 is the circuit diagram of FIG. 6 including third and fourth relays coupled between the filter capacitor and the output.

[0020] FIG. 8 is a graph of instantaneous grid voltage, current, and power sourced by a single phase of the grid under unity power-factor operation.

[0021] FIG. 9 is a graph of idealized operation of a three-phase/single-phase, single stage on-board charger, using one phase as an output active filter.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENT

[0022] Referring now to FIG. 1, a three-phase/single-phase on-board charger (OBC) is illustrated and generally designated 10. As discussed below, one DAB module of the OBC 10 is optionally used as the switch-mode and inductive elements of an output active filter and employs a single relay on the primary, high-side DC linkage to dynamically switch from a three-phase configuration when only a single-phase connection is detected.

[0023] More specifically, the OBC 10 is coupled to a three-phase electrical grid or a single-phase electrical grid 12. The OBC 10 includes a controller 14 for providing control signals to each of three DAB module 16, 18, 20, each with eight controllable switches. The controllable switches of the DAB modules 16, 18, 20 are operated by the controller 14 to provide a DC voltage to a battery 22, for example a vehicle battery. The controller 14 is also operable to detect a single-phase connection and a three-phase connection and is operable to control operation of one or more relays 24 coupled to a filter capacitor 32. Three grid synchronous rectifiers 26, 28, 30 provide a varying DC voltage to each DAB module 16, 18, 20.

[0024] During three-phase operation, each DAB module 16, 18, 20 is responsible for power factor correction of a single alternating current. The resulting DC output is achieved through the combination of all three DAB outputs. When applied to a three-phase grid, the isolated AC/DC system can take advantage of the 120° shift between each phase of the grid voltage. When the phase shift is 120° and the amplitude is equivalent between each voltage sinusoid, the grid is said to be balanced. This means that the sum of all three-phase voltages at any time t will be equal to zero as will, by extension, the phase currents and all their harmonics, given a unity power factor.

[0025] During single-phase operation, and to cancel the second-order harmonic in a single-phase system, one DAB module 20 from the three-phase system is dynamically repurposed as the switch-mode and inductive elements of an output active filter. Once connected to the filter capacitor 32, optionally a capacitor bank, the solo DAB module is operated bi-directionally, about 180° out of phase with the other two DAB modules 16, 18 to achieve active filtering. While three possible embodiments are shown in FIGS. 1 through 3, the embodiment of FIG. 1 is most advantageous for its lower conduction losses and additional separation from the grid, and is therefore discussed in further detail below.

[0026] By using one module 20 as an active filter, the hardware utilization of the entire system is maximized while the number of additional hardware and software requirements are minimized. Only the relay mechanism 24, filter capacitor 32, and a voltage sensor 34 across the filter capacitor 32 are required in addition to the existing hardware for three-phase operation. No additional PWM channels, only one additional ADC channel, and potentially as few as one additional GPIO output are required from the primary controller. The inductive component of the active filter is provided by the transformer and the output sensors to control the reactive power are already in place for three-phase operation. Furthermore, because the control algorithm can be modulated bi-directionally through zero power, only a new power references need be applied to the same open loop modulation algorithm, meaning the control loop maintaining the capacitor voltage can be designed using the same transfer function as the other two modules.

[0027] An on-board charger 10 in accordance with a second embodiment is illustrated in FIG. 2. This is embodiment differs from the embodiment of FIG. 1 in that the primary-side full bridge of each DAB 16, 28, 20 now includes a matrix converter having multiple bidirectional semiconductor switches for each phase of the electrical grid 12. In addition, the filter capacitor 32 is connected to the input side of the matrix converter for the third DAB, or “Matrix DAB 20” as depicted in FIG. 2. As also shown in FIG. 3, the filter capacitor 32 is connected to the input side of the third grid synchronous rectifier 30. The embodiments of FIGS. 2 and 3 are otherwise functionally similar to the embodiment of FIG. 1, in that each Matrix DAB or each DAB module is responsible for power factor correction of a single alternating current when connected to a three-phase grid, with one Matrix DAB or DAB module being repurposed as the switch-mode and inductive element of an active filter when connected to a single-phase grid.

[0028] The relay mechanism 24 may be any device that breaks the grid connection and simultaneously connects the filter capacitor. This may be realized with a single device, such as a single-pole, double-throw type mechanical relay, or with a combination of devices, such as complementary switched, solid-state or mechanical relays. FIG. 4 shows three device agnostic embodiments, in which a relay is made up of one or more devices. While either the grid, the filter capacitor, or neither may be connected to the DAB module 20, both being connected to the DAB simultaneously would be considered a fault condition. A relay in the form of FIG. 4(a) and FIG. 4(c) may be preferred for this reason.

[0029] Implementation of the relays may have a variety of embodiments since only the electrical circuit must be broken to disconnect either the grid or the filter capacitor, as opposed to all physical connections. FIG. 5 shows six embodiments of relay placement that will sufficiently break electrical connection to either the grid or the filter capacitor from the DAB module. FIGS. 5a, 5c, and 5e, while viable, are less desirable as the rectifier will add thermal losses during the active filter configuration that can be avoided by using the configures in FIGS. 5b, 5d, and 5f. Of those, FIG. 5d and FIG. 5f are most desirable from a cost and space optimization standpoint while FIG. 5b may be preferred from an isolation or EMI perspective. The embodiment of FIG. 1 shows the relay placement in FIG. 5d, while FIG. 6 shows the relay placement of FIG. 5b. FIG. 7 shows a further embodiment in which the filter capacitor 32 is coupled to the output rail voltage through third and fourth relays 25. In this embodiment, a total of four relays are used, which allow for the filter capacitor 32 to be switched between the output rail voltage in three-phase mode and the input DC linkage during single-phase mode. Consequently, the filter capacitor 32 is used both in three-phase operation and single-phase operation. In three-phase operation, switches Sr7 and Sr8 are closed such that the filter capacitor 32 reduces the output current ripple to the battery 22 and generally increases the ability to absorb transients on the grid so that they are not seen by the battery. In single-phase operations, switches Sr7 and Sr8 are open. The configuration in FIG. 7 therefore allows for maximum utilization of the filter capacitor 32 irrespective of the grid configuration. Depending upon the particular system, connecting the filter capacitor 32 to the output rail voltage could increase the output capacitance five to six times, while also greatly increasing the ability to supply transient demands on the output bus from other systems connected to the battery.

[0030] An additional advantage of placing the relays on the DC linkage between the unfolded rectifier and the DAB primary full-bridge is that it allows the rectifier to short its unused phase to neutral and add an additional conduction path to the neutral line. When switching from the three-phase and single-phase operation, if one DAB module is used as an active filter while the other two work in parallel to supply power to the output, the neutral connection must handle the return current of both phase connections. By shorting the neutral to the third, unused phase, through the unused rectifier, balance is restored between the neutral and phase connections.

[0031] The principle of operation of the OBC 10 will now be described. The control algorithm used to modulate the power of each phase's DAB module allow the instantaneous power through each to be controlled to any reference waveform. Therefore, the power reference supplied to the third DAB module 20, being used as the active filter, need merely be formulated to destructively interfere with the undesired output harmonics created by the power modulation of the other DAB modules. To illustrate this concept, FIG. 8 shows the power command needed to draw 14 kW, average power, from a 277 VRMS single-phase grid with unity power factor. This would therefore be the power reference applied to the first two DAB modules (16), (18) in FIG. 1. Assuming an idealized system, the output power, P.sub.out, would equal the input power, P.sub.grid, as a 120 Hz sine wave with a 14 kW amplitude and 14 kW DC offset. The desired output power is the average power output, P.sub.avg, plotted in FIG. 9. Therefore, the power that must be supplied to the output to cancel the output harmonic is P.sub.ant=P.sub.avg−P.sub.out. If P.sub.out is represented by the expression 14k*sin(120πt)+14 kW, and if P.sub.avg is represented by the expression 14 kW, then P.sub.act is equal to −14k*sin(120πt), which has an RMS value of P.sub.avg/√2W and a net contribution of OW. During the negative portion of P.sub.act in FIG. 9, the filter DAB module 20 is drawing power away from the output and storing that energy to the filter capacitor 32. This is the region in which the PFC DABS are supplying more power than the desired average. During the region where P.sub.act is positive, the filter DAB module 20 is pulling the stored energy out of the filter capacitor 32 and delivering it to the output. This is the region where the PFC DAB modules 16, 18 are delivering less power than desired. In this way, the load only sees the average power as the desired DC output.

[0032] The above description is that of current embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.