REDUNDANCY OF A RESONANT CONVERTER STAGE BY FREQUENCY ADAPTATION
20220385176 · 2022-12-01
Inventors
Cpc classification
H02M3/015
ELECTRICITY
H02M1/0009
ELECTRICITY
H02M1/325
ELECTRICITY
H02M1/0058
ELECTRICITY
H02M3/33523
ELECTRICITY
H02M3/33571
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
A resonant DC/DC converter which has a first DC link, preferably including a first DC link capacitor; a DC/AC converter which has a first plurality of N>1 converter bridges connected in parallel to the first DC link; each converter bridge comprising a plurality of switches each of which may be switched between a conducting state and a non-conducting state. The resonant DC/DC converter also includes an AC intermediate circuit having an input connected to an output of the DC/AC converter and comprising: a transformer, preferably a medium frequency transformer, having a primary side and a secondary side; the primary side comprising at least one primary winding; a first plurality of N capacitors, wherein for each converter bridge, a different one from the first plurality of capacitors is connected between said converter bridge and the at least one primary winding.
Claims
1. A resonant DC/DC converter, comprising: a) a first DC link; b) a DC/AC converter comprising a first plurality of N>1 converter bridges connected in parallel to the first DC link; each converter bridge comprising a plurality of switches, in particular semiconductor switches, each of which may be switched between a conducting state and a non-conducting state; c) an AC intermediate circuit connected to the DC/AC converter and comprising i) a transformer having a primary side and a secondary side; with the primary side comprising at least one primary winding; d) a first plurality of N capacitors, wherein e) for each converter bridge, a different one from the first plurality of capacitors is connected between said converter bridge and the at least one primary winding; f) a control unit configured to switch switches of the inverter bridges between the conducting and the non-conducting state or vice versa with a switching frequency to supply an AC current and/or voltage to the AC intermediate circuit; g) a plurality of N current sensing means (17), wherein for each inverter bridge a different one of the plurality of current sensing means is provided for monitoring a current through said converter bridge; h) the control unit is configured to determine whether a current through one of the inverter bridges deviates from an expected value; and to adapt, in particular increase, the switching frequency the current through one of the inverter bridges deviates from the expected value.
2. The resonant DC/DC converter according to claim 1, wherein the control system is configured to adapt the switching frequency according to an adapted switching frequency
3. The resonant DC/DC converter according to claim 1, wherein the control unit is configured to determine whether a current through one of the inverter bridges deviates from an expected value by determining whether said current, in particular an absolute value of said current, is smaller than a given threshold.
4. The resonant DC/DC converter according to claim 1, wherein the control unit is configured to determine whether a current through one of the inverter bridges deviates from an expected value by determining whether said current is at least approximately zero, in particular smaller than 1/100, 1/1000 or 1/10000 of a rated, nominal and/or maximum current of the inverter bridge.
5. The resonant DC/DC converter according to claim 1, wherein if the control unit is configured to, upon determination that the current through one of the inverter bridges deviates from an expected value, deactivate said inverter bridge.
6. The resonant DC/DC converter according to claim 1, wherein for each converter bridge, a different one from the plurality of current sensing means is provided between said converter bridge and the at least one primary winding, in particular between said converter bridge and the capacitor connected between said converter bridge and the at least one primary winding.
7. The resonant DC/DC converter according to claim 1, wherein AC current sensors are used as current sensing means for measuring an AC current output by the converter bridges.
8. A method for controlling a resonant DC/DC converter, said converter comprising a) a first DC link; b) a DC/AC converter comprising a first plurality of N>1 converter bridges connected in parallel to the first DC link; each converter bridge comprising a plurality of semiconductor switches each of which may be switched between a conducting state and a non-conducting state; c) an AC intermediate circuit connected to the DC/AC converter and comprising i) a transformer having a primary side and a secondary side; with the primary side comprising at least one primary winding; d) a first plurality of N capacitors, wherein e) for each converter bridge, a different one from the first plurality of capacitors is connected between said converter bridge and the at least one primary winding; f) a control unit configured to switch semiconductor switches of the inverter bridges between the conducting and the non-conducting state or vice versa with a switching frequency f.sub.res to supply an AC current and/or voltage to the AC intermediate circuit; the method comprising the steps of: g) for each converter bridge, monitoring a current through said inverter bridge; h) determining whether the current through a first inverter bridges deviates from an expected value; i) adapting, in particular increasing, the switching frequency if the current through a first inverter bridges deviates from the expected value.
9. The method according to claim 8, wherein the switching frequency f.sub.res is adapted to an adapted switching frequency
10. The method according to claim 8, wherein determining whether a current through one of the inverter bridges deviates from an expected value is performed by determining whether said current, in particular an absolute value of said current, is smaller than a given threshold.
11. The method according to claim 8, wherein determining whether a current through one of the inverter bridges deviates from an expected value is performed by determining whether said current is at least approximately zero, in particular smaller than 1/100, 1/1000 or 1/10000 of a rated, nominal and/or maximum current of the inverter bridge.
12. The method according to claim 8, further comprising the step of, upon determination that the current through a first inverter bridges deviates from an expected value, deactivating said first inverter bridge.
13. The method according to claim 8, further comprising the step of a) providing a plurality of N current sensing means (17); b) for each converter bridge, measuring the current trough said inverter bridge by a different one from the plurality of current sensing means provided between said converter bridge and the plurality of primary windings, in particular between said converter bridge and the capacitor connected between said converter bridge and the plurality of primary windings.
14. A control unit for controlling a resonant DC/DC converter according to the method of claim 8.
15. A computer program product comprising instructions which, when said instructions are executed by a data processing system, cause the data processing system to carry out the method according to 8.
16. The resonant DC/DC converter according to claim 1, wherein the first DC link comprises a first DC link capacitor.
17. The resonant DC/DC converter according to claim 1, wherein the transformer is a medium frequency transformer.
18. The resonant DC/DC converter according to claim 1, wherein the primary side comprises a plurality of M>1 windings; each of the first plurality of N capacitors is connected between one of the converter bridges and a common node; and the resonant DC/DC converter further comprises a second plurality of M capacitors, wherein each of the second plurality of M capacitors is connected between the common node and a different one of the plurality of primary windings.
19. The method according to claim 8, wherein the first DC link comprises a first DC link capacitor.
20. The method according to claim 8, wherein the transformer is a medium frequency transformer.
21. The method according to claim 8, wherein the primary side comprises a plurality of M>1 windings; each of the first plurality of N capacitors is connected between one of the converter bridges and a common node; and the resonant DC/DC converter further comprises a second plurality of M capacitors, wherein each of the second plurality of M capacitors is connected between the common node and a different one of the plurality of primary windings.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0193] The subject matter of the invention will be explained in more detail in the following text with reference to exemplary embodiments which are illustrated in the attached drawings.
[0194]
[0195]
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[0198] In principle, identical reference symbols in the figures denote identical features or elements.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0199]
[0200]
[0201]
[0202] In the embodiments as shown in
[0203] Converter bridges for relatively low current employing low-cost discrete off-the-shelf components may thus be used, and connected them via split resonant capacitors (C.sub.resA1, C.sub.resA2, C.sub.resA3, . . . C.sub.resAi) to a common point, in particular common node C, from where the medium frequency transformers (MFT) primary winding is connected. In case the primary winding is composed of parallel wires, further components (C.sub.resB1, C.sub.resB2, . . . C.sub.resBi) of the split resonant capacitor C.sub.res allow current balancing in the transformer wires as well, with an effective capacitance given by
[0204] If the multiple converter bridges employ low-current power semiconductors, gate drivers may be realized in very low-cost, e.g. boot-strap design which makes the required higher number of gate drivers no relevant cost factor any more. A potentially resulting reduced system reliability due to a significantly increased number of components and gate drivers is addressed by means of the switching frequency adaptation in accordance with the invention.
[0205] Generation of circulating currents, in particular in a configuration of two windings connected in parallel without impedance elements in between, and with each winding comprising a plurality of turns, may be understood as follows: Each of the turns is exposed to a magnetic stray field, e.g. in a windings window formed by a core of the transformer. Parallel litz wires forming individual windings which are connected at input and output terminals of the transformer form a loop which is exposed to the magnetic stray field. The magnetic stray field changes with the MFT's operating frequency, resulting in a voltage which drives a circular current in this loop. The circulating current adds to a nominal current in the MFT which may result in one litz wire carrying more than half of the nominal current, and the parallel one carrying accordingly less than half of the nominal current. If the circulating current is large enough, one litz wire can carry more than a total nominal current, and then the parallel one carries a negative (180° phase-shifted) current. In this way, not only is a total available copper cross section effectively reduced by 50%, but additional losses are introduced, and a maximum output power of the MFT is reduced by a factor two or more.
[0206] In the following the impact of losing one or more split resonant capacitors on the resonance frequency of the converter due to e.g. a failure of a converter bridge leg is discussed. The sum of all converter-side capacitors C.sub.resA1, C.sub.resA2, and C.sub.resA3, is referred to as as C.sub.resA and the sum of all primary-winding-side capacitors C.sub.resB1 and C.sub.resB2 as C.sub.resB, see equations (1) and (2). The resonant capacitance C.sub.res is defined in equation (3), and, as shown in equation (4), depends on transformer stray inductance L.sub.s and a selected switching frequency f.sub.p of the half bridges, which preferably is slightly lower than a resonance frequency f.sub.res in order to operate at minimum switching losses, in particular by utilizing soft f.sub.res switching.
[0207] If n out of N converter bridges fail, and, accordingly, n split capacitors (each of capacitance C.sub.resAi) are lost, an effective resonant capacitance C.sub.res.sup.Fail changes according to equation (5), and the resonant frequency changes according to equation (6). The control scheme in accordance with the invention would adjust the switching frequency of the remaining bridge legs according to (6) in for the embodiment as shown in
[0208] For the case with no primary-winding-side split capacitors (C.sub.res=C.sub.resA, no C.sub.resB as in the embodiment shown in
[0209] If a converter bridge becomes defective with its switches in the non-conducting state, its output current becomes zero, and this will be detected. If converter bridge becomes defective with its switches in the conducting state, some circuit breaker has to disconnect the affected converter, and its monitored output current becomes zero as well. Therefore, there the method in accordance with the invention works independently on a kind of converter bridge failure.
[0210]
[0211] In all embodiments shown, the secondary side of the DC/DC converter (as shown on the right hand side of
[0212] Advantageous characteristics of the invention are: [0213] High level of redundancy resulting in high reliability. [0214] Enables reliable low-cost inverter based on off-the-shelf discrete power devices. [0215] High level of modularity and scalability due to passive current-sharing between paralleled bridge legs. [0216] No extra components are required. Splitting the resonant capacitor as proposed keeps a total capacitor/inductor size, in particular a total/summed capacitance or inductance, unchanged. [0217] Allows low-cost realization of resonant DC/DC converter cells, employing and/or enabling off-the-shelf power semiconductor switches for high current applications simply by adding further half bridges. [0218] Allows low-cost realization of resonant DC/DC converter cells using wide bandgap semiconductor switches for high current applications, which would otherwise become increasingly difficult due to fast switching speeds and smaller chip size (as compared to non-wide bandgap semiconductor switches). [0219] No theoretical limitation of a number (Nor N) of parallel converter bridges, i.e. power semiconductor switches. [0220] Simple, robust, no active current balancing control required. [0221] Maximum and/or nominal electric power per MFT may be increased, due to an increase of a maximum current a single MFT can handle. This is key to building economically efficient MFTs. In higher-power (and thus larger) MFTs, an insulation effort, in particular a volume required for sufficient insulation is, in a relative sense, reduced. An alternative way of providing higher power via higher current would be to parallel-connect entire resonant converter or dual active bridge converter cells in an SST, or even to parallel-connect entire SSTs, and thus the number of MFTs required. But this would not increase a power level of the individual MFTs. [0222] Circulating currents in parallel transformer windings which are built from parallel wires may be efficiently suppressed due to split resonant capacitors or split energy transfer inductors which block such currents—this also enables employment of more common litz wire of smaller cross-section, which is potentially probably cheaper, and may be manufactured using reduced effort and resources. [0223] Very general concept for DC/DC resonant converters that have to deal with hundreds of amps; not only cells in MV-grid connected SSTs but also for high-power low-voltage applications, as e.g. required in various EV fast charger topologies.
[0224] Unless specified otherwise, a control unit, also referred to as a control system or controller, may be any (first) device, apparatus, system, unit, etc. configured for and/or capable of managing, commanding, directing, or regulating another (second) device, apparatus, sensor, unit, etc., wherein both device, apparatus, system, unit, etc., may be part of a higher lever or superordinate (third) device, apparatus, sensor, unit, etc. The control unit may apply open-loop control or close-loop control, wherein the latter may in particular take into account feedback from sensors.
[0225] The control unit may comprise and/or be implemented it least in part on a “computer,”, “processor”, “processing device”, “central processing unit (CPU)”, “computing device”, which terms shall not be limited to just those devices literally, but shall broadly refer to a data processing system, also including a microcontroller, a microcomputer, a programmable logic controller (PLC), and application specific integrated circuit, and other programmable circuits, wherein these terms may be used interchangeably herein. In embodiments described herein, memory may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD), a USB stick and/or a flash memory card (e.g. CF, SD, miniSD, microSD) may also be used. Also, in the embodiments described herein, input channels may comprise, but are not limited to, computer peripherals associated sensors or sensing means, or with an operator interface such as a mouse and a keyboard. Furthermore, in the exemplary embodiments, additional output channels may include, but not be limited to, an operator interface monitor.
[0226] Further, as used herein, the terms “software” and “firmware” are interchangeable and include any computer program which may be stored in memory for execution by computers as defined above, workstations, clients, and/or servers.
[0227] As used herein, the term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method of technology for short-term and/or long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, the methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer-readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a computer as defined above, cause the computer to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” may include all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including without limitation, volatile and non-volatile media, and removable and non-removable media such as firmware, physical and virtual storage, CD-ROMS, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being transitory, propagating signal.
[0228] Unless specified otherwise, a connection, in particular between any two entities, including in particular nodes, points, terminals, elements, devices, etc. or combinations thereof, as used throughout this patent application refers to an electrically conductive connection, as in particular established by a wire, cable, busbar, a conductive track, trace or line on e.g. a (printed) circuit board, solder, etc. The electrically conductive connection is preferably at least substantially direct, in particular without any discrete elements, as, in particular, resistors, capacitors, inductors, or other passive or active elements or devices connected between the connected entities. The electrically conductive connection thus has at least essentially negligible resistance, capacitance and inductance, preferably at least essentially zero resistance, capacitance and inductance. In particular, resistance, capacitance and inductance of the electrically conductive connection are exclusively parasitic by nature. Further, resistance, capacitance and inductance of the electrically conductive connection significantly smaller (preferably by a factor of 1/100, 1/1000 or 1/10000) than resistances, capacitances and impedances of resistors, capacitors or inductors, respectively, connected by the electrical conductive connection, and/or comprised by an electric circuit or network which comprises the electrically conductive connection.
[0229] Unless specified otherwise, an electric connection or electrical connection is identical to connection as defined above.
[0230] Unless specified otherwise, if two entities, including in particular nodes, points, terminals, elements, devices, etc. or combinations thereof, are said to be connected, electrically connected or to be (electrically) connected together, a connection as defined above exists between the two entities.
[0231] Unless specified otherwise, if a first and a second entity, including in particular a first and second node, point, terminal, element, device, etc. or combinations thereof, are said to be connected via a third entity, including in particular a third node, point, terminal, element, device, or with such a third entity (in) between, a connection as described above exists between the first and third entities as well as between the third and second entities. However, no connection as described above, in particular no at least substantially direct connection exists between the first and second entities. If explicitly specified, the third element may in particular also be a connection, in particular a conductor, wire, cable, busbar etc. In such case, it may be assumed that no connection as described above other than the specified one is present.
[0232] Unless stated otherwise, it is assumed that throughout this patent application, a statement a≈b implies that |a-b|/(|a|+|b|)<10, preferably |a-b|/(|a|+|b|)<100, wherein a and b may represent arbitrary variables as described and/or defined anywhere in this patent application, or as otherwise known to a person skilled in the art. Further, a statement that a is at least approximately equal or at least approximately identical to b implies that a≈b, preferably a=b. Further, unless stated otherwise, it is assumed that throughout this patent application, a statement that a>>b, or that a is significantly larger or much larger than b, implies that a>10b, preferably a>100b; and statement that a<<b, or that a is significantly smaller or much smaller than b implies that 10a<b, preferably 100a<b. Further, a statement that two values a and b substantially deviate from one another, or differ significantly, implies that a≈b does not hold, in particular that a>>b or a<<b.
[0233] Unless stated otherwise, N, M, O, N′, M′, O′, are used throughout this patent application to represent integer numbers.
[0234] This description and the accompanying drawings that illustrate aspects and embodiments of the present invention should not be taken as limiting the claims defining the protected invention. In other words, while the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of this description and the claims. In some instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the invention. Thus, it will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different and/or individual embodiments as described above and below. Embodiments in accordance with the invention may, in particular, include further and/or additional features, elements, aspects, etc. not shown in the drawings or described above.
[0235] The disclosure also covers all further features shown in the Figures, individually, although they may not have been described in the afore or following description. Also, individual alternatives of the embodiments described in the Figure and the description and individual alternatives of features thereof can be disclaimed from the subject matter of the invention or from disclosed subject matter. The disclosure comprises subject matter consisting of the features defined in the claims or the exemplary embodiments as well as subject matter comprising said features.
[0236] Furthermore, in the claims the word “comprising” does not exclude further or additional features, elements, steps etc., and the indefinite article “a” or “an” does not exclude a plurality. A single unit or step may fulfil the functions of several features recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The terms “essentially”, “about”, “approximately” and the like in connection with an attribute, property or a value particularly also comprise exactly the attribute, property or value, respectively, as stated. The term “approximately” or “about” in the context of a given numerate value or range refers to a value or range that is, e.g., within 20%, within 10%, within 5%, or within 2% of the given value or range, and, in particular, also comprises the exact value or range as stated. Components described as coupled or connected may be electrically or mechanically directly coupled, or they may be indirectly coupled via one or more intermediate components. Any reference signs in the claims shall not be construed as limiting the scope.