Power distribution architecture with series-connected bus converter
11075583 · 2021-07-27
Assignee
Inventors
Cpc classification
H02M1/0064
ELECTRICITY
H02M3/158
ELECTRICITY
H02M1/0093
ELECTRICITY
H02M3/33576
ELECTRICITY
H02M1/0058
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
Abstract
Apparatus for power conversion are provided. One apparatus includes a power converter including an input circuit and an output circuit. The power converter is configured to receive power from a source for providing power at a DC source voltage V.sub.S. The power converter is adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio K.sub.DC=V.sub.OUT/V.sub.IN at an output current, wherein V.sub.IN is an input voltage and V.sub.OUT is an output voltage. The input circuit and at least a portion of the output circuit are connected in series across the source, such that an absolute value of the input voltage V.sub.IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V.sub.S minus a number N times the absolute value of the output voltage V.sub.OUT, where N is at least 1.
Claims
1. A method of converting power received from a source at a DC source voltage, V.sub.S, that may vary over a first voltage range for delivery to electronic circuitry, the method comprising: providing a first power conversion stage having an input circuit and an output circuit, the first power conversion stage being adapted over the first voltage range to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K.sub.DC, at an output current, wherein an input voltage V.sub.IN is applied to the input circuit and an output voltage V.sub.OUT is produced by the output circuit of the first power conversion stage, and wherein the substantially fixed voltage transformation ratio can be represented as K.sub.DC=V.sub.OUT/V.sub.IN; connecting the input circuit to receive power from the source; providing a power regulation stage having a regulator input connected to receive power from the output circuit of the first power conversion stage at the output voltage, V.sub.OUT, and a regulator output connected to supply power to a respective semiconductor load at a load voltage, V.sub.Load, the power regulation stage being separated by a distance from the first power conversion stage; providing a galvanic connection between the input circuit of the first power conversion stage and the output circuit of the first power conversion stage; using an inductive component and one or more power switches in the input circuit, the output circuit, or both of the first power conversion stage; reducing a voltage across the one or more switches prior to turning ON said one or more switches using a current flowing in the inductive component to charge and discharge capacitances in the first power conversion stage; and setting the voltage transformation ratio, K.sub.DC=V.sub.OUT/V.sub.IN, of the first power conversion stage to a value that is less than 1.
2. The method of claim 1, further comprising: providing a system circuit board having a power input for receiving power from the source; assembling the first power conversion stage as a self-contained assembly to the system circuit board; assembling the second power conversion stage to the system circuit board; assembling the electronic circuitry to the system circuit board; and providing electrical connections in the system circuit board for (a) conducting power from the power input to the system circuit board and the input of the first power conversion stage, (b) conducting power from the output of the system circuit board to the regulator input of the second power conversion stage, and (c) conducting power from the regulator output to the electronic circuitry.
3. The method of claim 2, wherein the electronic circuitry includes an integrated circuit.
4. The method of claim 2, further comprising providing a switch controller in the first power conversion stage, the switch controller being adapted to operate the power switches in a series of converter operating cycles, each converter operating cycle being characterized by two power transfer intervals of essentially equal duration, each interval having a duration less than the characteristics resonant period, during which one or more of the switches are ON and power is transferred from the input to the output via a transformer.
5. The method of claim 4, further comprising providing a DC blocking capacitor in the input circuit or the output circuit or both.
6. The method of claim 4, further comprising providing control circuitry referenced to a system ground.
7. The method of claim 2, wherein the first power conversion stage produces a polarity change between the input voltage and the output voltage.
8. The method of claim 2, further comprising providing control circuitry referenced to a system ground.
9. The method of claim 2, further comprising setting the source voltage, V.sub.S, to a nominal value between 38 volts and 55 volts DC.
10. The method of claim 9, further comprising setting the source voltage, V.sub.S, to 50 volts DC nominal.
11. The method of claim 2, further comprising setting the voltage transformation ratio, K.sub.DC=V.sub.OUT/V.sub.IN, of the first power conversion stage to a value that produces a nominal output voltage at or near 10 volts DC.
12. The method of claim 2, further comprising setting the voltage transformation ratio, K.sub.DC=V.sub.OUT/V.sub.IN, of the first power conversion stage to a value that is ¼ or less.
13. The method of claim 3, further comprising locating the first power conversion stage at or near an input on a first printed circuit board for receiving power from the source and locating the power regulation stage at or near an integrated circuit on the first printed circuit board, wherein the integrated circuit receives power from power regulation stage.
14. The method of claim 2, wherein one or more power switches are used in the output circuit of the first power conversion stage and further comprising controlling the one or more switches in the output circuit to turn ON and OFF at times of essentially zero current.
15. The method of claim 14, wherein one or more power switches are used in the input circuit of the first power conversion stage and further comprising controlling the one or more switches in the input circuit to turn ON and OFF essentially at times when a resonant portion of current is essentially zero.
16. The method of claim 2, further comprising forming a resonant circuit including the inductive component, the resonant circuit having a Q less than 13.
17. The method of claim 2, further comprising forming a resonant circuit including the inductive component, the resonant circuit having a Q less than 8.
18. The method of claim 2, further comprising forming a resonant circuit including the inductive component, the resonant circuit having a characteristic resonant frequency greater than 500 KHz and a Q less than 10.
19. The method of claim 16, wherein the resonant circuit is a series resonant circuit.
20. The method of claim 14, wherein the one or more switches in the output circuit are used to rectify power.
21. The method of claim 2, further comprising using a sinusoidal current waveform in the output circuit to limit slew rates in one or more switches used to rectify power in the output circuit.
22. An apparatus comprising: a bus converter having an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K.sub.DC, at an output current, wherein an input voltage V.sub.IN is applied to the input circuit and an output voltage V.sub.OUT is produced by the output circuit of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K.sub.DC=V.sub.OUT/V.sub.IN; wherein the input circuit and the output circuit are coupled by a transformer, the transformer including at least two windings; wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are connected in series across a source such that an absolute value of the input voltage V.sub.IN applied to the input circuit is approximately equal to the absolute value of a DC source voltage V.sub.S minus a number N times the absolute value of the output voltage V.sub.OUT, where N is at least 1.
23. The apparatus of claim 22, wherein the output circuit comprises two secondary windings, each secondary winding comprising a same number of secondary turns.
24. The apparatus of claim 23, wherein the input circuit comprises at least one primary winding having a first number of turns magnetically coupled to the secondary windings and at least two primary power switches connected to drive the at least one primary winding; and wherein the secondary winding has a second number of turns, and wherein the substantially fixed voltage transformation ratio, K.sub.DC, is a function of a ratio of the first number of turns to the second number of turns.
25. The apparatus of claim 24, wherein the secondary windings are connected to form a center-tap winding with two terminal ends and a center tap.
26. The apparatus of claim 25, wherein N is equal to approximately 2, such that the input voltage V.sub.IN is approximately equal to the DC source voltage VS minus 2 times the output voltage V.sub.OUT.
27. The apparatus of claim 25, wherein the output circuit comprises at least one secondary power switch connected to a respective terminal end of the secondary winding.
28. The apparatus of claim 27, wherein each of the terminal ends of the secondary winding are selectively connected to a common terminal through a respective secondary power switch and the center tap is connected to supply the output voltage V.sub.OUT with respect to the common terminal.
29. The apparatus of claim 28, wherein the input circuit includes at least two primary switches connected together to drive a first end of the at least one primary winding.
30. The apparatus of claim 29, wherein the input circuit includes at least two additional primary switches connected together to drive a second end of the at least one primary winding.
31. The apparatus of claim 30, wherein the bus converter further comprises: a series resonant circuit including the at least one primary winding and at least one resonant capacitor in series with the at least one primary winding, the series resonant circuit having a characteristic resonant frequency and a characteristic resonant period, the at least two primary switches being connected to drive the series resonant circuit; and a switch controller adapted to operate the at least two primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristic resonant period, during which one or more of the at least two primary switches are ON and power is transferred from the input circuit to the output circuit via a transformer.
32. The apparatus of claim 31, wherein the bus converter is a self-contained assembly adapted to be installed as a unit.
33. The apparatus of claim 22, wherein the bus converter comprises: a resonant circuit including the transformer having a characteristic resonant frequency and a characteristic resonant period, the input circuit including two or more primary switches connected to drive the resonant circuit and the output circuit being connected to receive power from the transformer; and a switch controller adapted to operate the two or more primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristic resonant period, during which one or more of the two or more primary switches are ON and power is transferred from the input circuit to the output circuit via the transformer.
34. The apparatus of claim 22, wherein the bus converter is a self-contained assembly adapted to be installed as a unit.
35. The apparatus of claim 22, wherein both the input circuit and the output circuit comprise full-bridge circuits, wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the substantially fixed voltage transformation ratio, K.sub.DC, is a function of a ratio of the first number of turns to the second number of turns.
36. The apparatus of claim 22, wherein the input circuit comprises at least one primary winding having a first number of turns magnetically coupled to the secondary winding and at least two primary power switches connected to drive the at least one primary winding; and the output circuit includes at least one secondary winding having a second number of turns, and wherein the substantially fixed voltage transformation ratio, K.sub.DC, is a function of a ratio of the first number of turns to the second number of turns.
37. The apparatus of claim 36, wherein the windings are connected to form a center-tap winding with two terminal ends and a center tap.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
DETAILED DESCRIPTION
(8) Power Distribution Architecture
(9) A power distribution system 50 is shown in
(10) One or more bus converters, e.g. bus converters 56, 57, may be connected to the power distribution bus 55 downstream from the front end 53 as shown in the example of
(11) The output of each bus converter 56, 57 may, in turn, provide power via its respective bus 58, 59 to a respective plurality of regulators, preferably at or near the point of load, such as point-of-load switching voltage regulators 60, 61. It should be understood that although two bus converters 56, 57 are shown in the example of
(12) The bus converters 56, 57 shown in the system of
(13) Series-Connected DC Transformer
(14) Referring to
(15) The voltage gain or voltage transformation ratio of a system as defined generally herein is the ratio of its output voltage to its input voltage at a specified current such as an output current. For the system 20 in
V.sub.IN=V.sub.S−V.sub.O. (1)
(16) Similarly as shown in
I.sub.O=I.sub.L−I.sub.IN. (2)
(17) The system voltage transformation ratio, K.sub.SYS, using the series-connected DC Transformer 25, may be expressed as a function of the DC Transformer voltage transformation ratio, K.sub.DC:
K.sub.SYS=K.sub.DC/(K.sub.DC+1) (3)
(18) The above equation (3) may be rearranged to express the DC Transformer 25 voltage transformation ratio, KDC, required in a series-connected system as a function of the system voltage transformation ratio, K.sub.SYS:
K.sub.DC=K.sub.SYS/(1−K.sub.SYS) (4)
(19) Referring to
(20) A series-connected SAC 200 is shown in
(21) Many contemporary applications use a voltage transformation ratio equal to ⅕ requiring an odd transformer turns ratio (N2/N1=⅕) which is generally not optimal. Referring to equation (4) above, the K.sub.SYS=⅕ bus converter may be implemented using a K.sub.DC=¼ series-connected topology (e.g. as shown in
(22) Note that the series-connected converter 200 may be implemented by connecting an off-the-shelf isolated DC Transformer, such as the isolated converter shown in
(23) Connecting the input and output of the DC Transformer 25 in series eliminates galvanic isolation between the input and output of the series-connected bus converter 20, which is counterintuitive. However, when used in the architecture of
(24) Efficiency
(25) The power processed by the isolated SAC shown in
(26)
(27) Each input switch (S1, S2, S3 and S4) in the full bridge input circuits (
P.sub.IN=2*V.sub.IN*I.sub.IN (6)
(28) Similarly, each output switch (S5, S6, S7 and S8) in the full bridge output circuit of
P.sub.OUT=2*V.sub.O*I.sub.O (7)
(29) Combining equations (6) and (7) and making the appropriate substitutions using K.sub.DC=V.sub.O/V.sub.IN and the corollary I.sub.IN=K.sub.DC*I.sub.O, the total power processed by the converters reduces to:
P=4*V.sub.O*I.sub.O (8)
(30) In the isolated converter of
P.sub.ISO=4*P.sub.Load (9)
(31) Neglecting fixed losses in the converter, the input current may be expressed as a function of the output current and voltage transformation ratio as follows:
I.sub.IN=I.sub.O*K.sub.DC (10)
(32) Combining equations (2), (4), and (10), the output current of the series-connected converter may be expressed as a function of load current and voltage transformation ratio as follows:
I.sub.O-Series=I.sub.L*(1−K.sub.SYS) (11)
(33) Substituting equation (11) into equation (8) produces the total power processed by the series-connected converter as a function of load power (P.sub.Load=V.sub.O*I.sub.L) and system voltage transformation ratio:
P.sub.SERIES=4*P.sub.Load*(1−K.sub.SYS) (12)
(34) Accordingly, the efficiency advantage of the series-connected converter over the isolated converter—the ratio of equations (12) and (9)—reduces to:
P.sub.SERIES/P.sub.ISO=(1−K.sub.SYS) (13)
(35) From equation (13) it can be seen that the series-connected converter offers a significant efficiency advantage. Consider a typical example for comparison, using a bus converter to convert power from a nominal 50 Volt power distribution bus for delivery to a 10 volt load (K.sub.SYS=⅕) at 100 amps: the series-connected converter processes only 80% of the power, offering a 20% efficiency savings compared to the isolated converter.
(36) In a typical isolated DC Transformer, like most DC-DC converters, the control circuitry is configured to operate from power drawn from the input producing a quiescent component of the input current. Use of such a converter, e.g. an off-the-shelf DC Transformer, in a series-connected configuration could, therefore, allow the quiescent input current to flow unregulated into a load connected to the output, which would be problematic while the power train is not operating and, therefore, incapable of regulating the output voltage. It may, for that reason, be desirable to clamp the output voltage using a zener diode, such as zener diode 26 in
(37) Configuring the control circuitry to reference the system ground in the integrated converter (rather than the input return in the off-the-shelf isolated converter) easily allows any interface signals to be ground-referenced (rather than output referenced) which is advantageous from the perspective of the system integrator.
(38) Center-Tap Secondary
(39) Another series-connected SAC 210 is shown in
(40) The converter 210 of
V.sub.IN-210=V.sub.S−2V.sub.O (14)
(41) as suggested by the addition of N2 turns in the output winding of the transformer. Also, each output switch (S5, S6, S7 and S8) in the converter 210 is subjected to twice the output voltage, V.sub.O, with the upper output switches (S5 and S7) each carrying an average of half of the input current, I.sub.IN, and the lower output switches (S6 and S8) each carrying an average of half of the difference between the load current, I.sub.L, and the input current, I.sub.IN. Using the same analysis as described above, summing the product of maximum voltage across (V.sub.n) and average current (I.sub.n) through each switch (N=1 through 8), the total power processed by the converter 210 of
P.sub.210=2*V.sub.IN*I.sub.IN+2*V.sub.O*I.sub.IN+2*V.sub.O*(I.sub.L−I.sub.IN) (15)
(42) Using the system voltage transformation ratio, K.sub.SYS=V.sub.O/V.sub.S in equation (14), the input voltage may be expressed as:
V.sub.IN-210=V.sub.O*((1/K.sub.SYS)−2) (16)
(43) Recognizing that in an ideal converter the input power equals the output power V.sub.S*I.sub.IN=V.sub.O*I.sub.L the input current may be expressed as:
I.sub.IN=K.sub.SYS*I.sub.L (17)
(44) Making the appropriate substitutions into equation (15), the total power processed by series-connected converter 210 (
P.sub.210=4*V.sub.O*I.sub.L*(1−K.sub.SYS) (18)
(45) which may be further reduced to express the total power processed by the series-connected converter 210 using a center-tap output winding as shown in
P.sub.210=4*P.sub.Load*(1−K.sub.SYS) (19)
(46) Which is the same result obtained in equation (12) above for the series-connected converter 200 in
(47) There may be certain advantages of one series-connected topology over the other depending upon the application. For example, the transformer in the converter 200 (
(48) Negative Input-Positive Output
(49) Referring to
|V.sub.IN-215|=|V.sub.S|−|V.sub.O| (20)
as also suggested by the transformer configuration. Also, the upper output switches (S5 and S7) each carry an average of half of the output current, I.sub.O, which equals the load current, I.sub.L in
P.sub.215=2*V.sub.IN*I.sub.IN+2*V.sub.O*I.sub.IN+2*V.sub.O*I.sub.L (21)
(50) which, when reduced using equations (17) and (20), becomes:
P.sub.215=4*P.sub.Load (22)
(51) A comparison of the power processed by the converter 215 (equation (22);
(52) The converters 20 (
|V.sub.IN|=|V.sub.S|−N*|V.sub.O| (23)
(53) The value of N will vary depending upon the converter topology used, e.g. a center-tap secondary or not, polarity reversing or not, etc. In the examples described above: N=1 for converters 20 (
(54) The disclosure is described above with reference to drawings. These drawings illustrate certain details of specific embodiments that implement the systems, apparatus, and/or methods of the present disclosure. However, describing the disclosure with drawings should not be construed as imposing on the disclosure any limitations that may be present in the drawings. No claim element herein is to be construed under the provisions of 35 U.S.C. § 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” Furthermore, no element, component or method step in the present disclosure is intended to be dedicated to the public, regardless of whether the element, component or method step is explicitly recited in the claims.
(55) It should be noted that although the disclosure provided herein may describe a specific order of method steps, it is understood that the order of these steps may differ from what is described. Also, two or more steps may be performed concurrently or with partial concurrence. It is understood that all such variations are within the scope of the disclosure.
(56) The foregoing description of embodiments of the disclosure have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosure. The embodiments were chosen and described in order to explain the principals of the disclosure and its practical application to enable one skilled in the art to utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated.