CONTROL METHOD FOR A DC-DC CONVERTER AND DC-DC CONVERTER

Abstract

The present invention relates to a power transmission in a DC-DC converter, in particular a phase-shifted full-bridge DC-DC converter from the secondary side to the primary side. In particular, an additional switching state which can reduce the power dissipation of the switching elements in the DC-DC converter, is provided.

Claims

1. A method (100) for controlling a phase-shifted full-bridge DC-DC converter (1) for an energy transmission from a secondary side to a primary side of the DC-DC converter (1), wherein a transformer (50) is arranged between the primary side and the secondary side of the DC-DC converter (1), and wherein the method (100) comprises electrically connecting, in a switching state, terminals (51, 52) of a primary side of the transformer (50) to one another, electrically connecting, in the switching state, terminals (53, 54) of a secondary side of the transformer (54 and electrically connecting terminals (21, 22) of a secondary side of the phase-shifted full-bridge DC-DC converter (1) to one another.

2. The method (100) as claimed in claim 1, wherein an electrical voltage (U_prim) at the primary side of the DC-DC converter (1) is greater than the product of an electrical voltage (U_sek) at the secondary side of the DC-DC converter (1) multiplied by a transformation ratio of the transformer (50).

3. The method (100) as claimed in claim 1, wherein the method (100) further comprises: connecting (110) a first terminal (53) of the secondary side of the transformer (50) to a first terminal (21) of the secondary side of the DC-DC converter (1), connecting a second terminal (54) of the secondary side of the transformer (50) to a second terminal (22) of the secondary side of the DC-DC converter (1), connecting a first terminal (51) of the primary side of the transformer (50) to a first terminal (11) of the primary side of the DC-DC converter (1), and connecting a second terminal (52) of the primary side of the transformer (50) to a second terminal (12) of the primary side of the DC-DC converter (1); connecting (120) the first terminal (53) of the secondary side of the transformer (50), the second terminal of the secondary side (54) of the transformer (50), the first terminal (21) of the secondary side of the DC-DC converter (1) and the second terminal (22) of the secondary side of the DC-DC converter (1); disconnecting (130) the connection between the second terminal (52) of the primary side of the transformer (50) and the second terminal (12) of the primary side of the DC-DC converter (1), and connecting the second terminal (52) of the primary side of the transformer (50) to the first terminal (11) of the primary side of the DC-DC converter (1); disconnecting (140) the connection between the first terminal (53) of the secondary side of the transformer (50) and the second terminal (54) of the secondary side of the transformer (50) and the connection between the first terminal (21) of the secondary side of the DC-DC converter (1) and the second terminal (22) of the secondary side of the DC-DC converter (1), and providing an electrical connection between the first terminal (21) of the secondary side of the DC-DC converter (1) and the second terminal (54) of the secondary side of the transformer (50) as well as between the second terminal (22) of the secondary side of the DC-DC converter (1) and the first terminal (53) of the secondary side of the transformer (50).

4. The method (100) as claimed in claim 3, wherein the method (100) further comprises: connecting (150) the second terminal (54) of the secondary side of the transformer (50) to the first terminal (21) of the secondary side of the DC-DC converter (1), connecting the first terminal (53) of the secondary side of the transformer (50) to the second terminal of the secondary side (22) of the DC-DC converter (1), connecting the second terminal (52) of the primary side of the transformer (50) to the first terminal (11) of the primary side of the DC-DC converter (1), and connecting the first terminal (51) of the primary side of the transformer (50) to the second terminal (12) of the primary side of the DC-DC converter (1); connecting (160) the first terminal of the secondary side (53) of the transformer (50), the second terminal (54) of the secondary side of the transformer (50), the first terminal (21) of the secondary side of the DC-DC converter (1) and the second terminal (22) of the secondary side of the DC-DC converter (1); disconnecting (170) the connection between the first terminal (51) of the primary side of the transformer (50) and the first terminal (11) of the primary side of the DC-DC converter (1), and connecting the first terminal (51) of the primary side of the transformer (50) to the second terminal (12) of the primary side of the DC-DC converter (1); disconnecting (180) the connection between the first terminal (53) of the secondary side of the transformer (50) and the second terminal (54) of the secondary side of the transformer (50), and disconnecting the connection between the second terminal (22) of the secondary side of the DC-DC converter (1) and the first terminal (21) of the secondary side of the DC-DC converter (1), and providing an electrical connection between the second terminal (22) of the secondary side of the DC-DC converter (1) and the first terminal (53) of the secondary side of the transformer (50) as well as between the first terminal (21) of the secondary side of the DC-DC converter (1) and the second terminal (54) of the secondary side of the transformer (50).

5. A phase-shifted full-bridge DC-DC converter (1), comprising a transformer (50) having a primary side and a secondary side; a first switching element (S1), which is arranged between a first primary terminal (11) and a first node (31), a second switching element (S2), which is arranged between the first node (31) and a second primary terminal (12), a third switching element (S3), which is arranged between the first primary terminal (11) and a second node (32), a fourth switching element (S4), which is arranged between the second node (32) and the second primary terminal (12), wherein the first node (31) is connected to a first primary terminal (51) of the transformer (50), and the second node (32) is connected to a second primary terminal (12) of the transformer (50); a fifth switching element (S5), which is arranged between a first secondary terminal (22) and a third node (41), a sixth switching element (S6), which is arranged between the third node (41) and a second secondary terminal (22), a seventh switching element (S7), which is arranged between the first secondary terminal (21) and a fourth node (42), an eighth switching element (S8), which is arranged between the fourth node (42) and the second secondary terminal (22), wherein the third node (41) is connected to a first secondary terminal (53) of the transformer (50), and the fourth node (42) is connected to a second secondary terminal (54) of the transformer (50); a control device, which is configured to control the first to eighth switching elements (S1 to S8) to electrically connect terminals (51, 52) of a primary side of the transformer (50) to one another, electrically connect terminals (53, 54) of a secondary side of the transformer (50), and electrically connect terminals (21, 22) of a secondary side of the phase-shifted full-bridge DC-DC converter (1) to one another.

6. The DC-DC converter (1) as claimed in claim 5, wherein a series inductance (60) is arranged between the first secondary terminal (21) and a connecting point between the fifth switching element (S5) and the seventh switching element (S7).

7. The DC-DC converter (1) as claimed in claim 5, wherein the transformer (50) has a low leakage inductance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Further features and advantages of the invention will be explained below with reference to the figures, in which:

[0021] FIG. 1 shows a schematic illustration of a basic circuit diagram, as forms the basis of a DC-DC converter in accordance with one embodiment;

[0022] FIG. 2 shows a timing diagram for a sequence of switching states, as forms the basis of a method for operating the DC-DC converter in accordance with one embodiment;

[0023] FIG. 3 shows a timing diagram for the switching states in a DC-DC converter in accordance with a further embodiment; and

[0024] FIG. 4 shows a schematic illustration of a flowchart, as forms the basis of a method for controlling a DC-DC converter in accordance with one embodiment.

DETAILED DESCRIPTION

[0025] FIG. 1 shows a schematic illustration of a basic circuit diagram, as forms the basis of a DC-DC converter 1, in particular a phase-shifted full-bridge DC-DC converter in accordance with one embodiment. The DC-DC converter 1 comprises, on the primary side, a terminal element 10 having a first primary terminal 11 and a second primary terminal 12. A DC voltage U_prim can be present between the first terminal 11 and the second terminal 12 of the primary side. Similarly, a terminal element 20 on the secondary side comprises a first secondary terminal 21 and a second secondary terminal 22. A DC voltage U_sek can be present between the first terminal 21 and the second terminal 22 of the secondary side. For example, the DC-DC converter 1 can be coupled on the primary side to a high-voltage power supply system of an electric vehicle, and the secondary side of the DC-DC converter 1 can be coupled to a low-voltage power supply system of an electric vehicle. However, in principle any other desired application possibilities for such a DC-DC converter 1 are also possible.

[0026] Furthermore, the DC-DC converter 1 has a first full-bridge 30, a second full-bridge 40 and a transformer 50. The transformer 50 is connected on the primary side to the first full-bridge 30 and on the secondary side to the second full-bridge 40.

[0027] The first full-bridge 30 comprises a first switching element S1, which is arranged between the first primary terminal 11 and a first node 31, a second switching element S2, which is arranged between the first node 31 and the second primary terminal 12, a third switching element S3, which is arranged between the first primary terminal 11 and a second node 32, and a fourth switching element S4, which is arranged between the second node 32 and the second primary terminal 12. The first node 31 is connected to a first terminal 51 of the primary side of the transformer 50, and the second node 32 is connected to a second primary terminal 52 of the transformer 50.

[0028] Similarly, the second full-bridge 42 comprises the four switching elements S5 to S8. The switching element S5 is connected on one side to a third node 41, and is electrically coupled on the other side to the first secondary terminal 21. The switching element S6 is arranged between the third node 41 and the second secondary terminal 22. The switching element S7 is arranged between a fourth node 42 and the first secondary terminal 22, and the switching element S6 is arranged between the fourth node 42 and the second secondary terminal 22.

[0029] A series inductance 60 can be provided between a connecting point at which the switching element S5 and the switching element S7 are connected to one another and the first secondary terminal 22. The third node 41 is connected to a first terminal 53 of the secondary side of the transformer 50, and the fourth node 42 is connected to a second secondary terminal 54 of the transformer 50.

[0030] Finally, a control device (not illustrated) is provided, which controls the switching elements S1 to S4 of the first full-bridge and the switching elements S5 to S8 of the second full-bridge in a suitable manner. In particular a switching sequence for an electrical energy transmission from the secondary side to the primary side of the DC-DC converter 1, as can take place, for example, by means of the control device, is explained in more detail below.

[0031] FIG. 2 shows a timing diagram for the switching states of the switching elements S1 to S8 of the full-bridges 30 and 40, as they can be provided during an energy transmission from the secondary side to the primary side of the DC-DC converter 1.

[0032] At time t0, in the first full-bridge 20 on the primary side in one diagonal branch, the first switching element S1 and the fourth switching element S4 are controlled, with the result that these switching elements are turned on. The switching elements in the other diagonal branch comprising the second and third switching elements S2 and S3, on the other hand, are open. Furthermore, the switching elements S5 and S8 in one diagonal branch of the second full-bridge 40 are on, and the switching elements S6 and S7 in the other diagonal branch are open. In this way, between t0 and t1, electrical power is transmitted from the secondary side to the primary side of the DC-DC converter. At time t1, the two remaining secondary-side switches S6 and S8 are likewise controlled and therefore turned on, with the result that all four secondary-side switches S5 to S8 are in the closed state. Therefore, the transformer current decreases very quickly as a result of the primary-side voltage, which is present across the leakage inductance of the transformer 50, and becomes negative. At time t2, the fourth switching element S4 switches off, and the third switching element S3 is controlled and is therefore turned on. The transformer current must therefore be negative at time t2 in order to achieve soft switching-on of the third switching element S3. In order to reduce the reactive current between time t2 and t3, therefore, a low absolute value for the transformer current at time t2 is preferred.

[0033] In this special switching state between t2 and t3, therefore, on the primary side the first switching element Si and the third switching element S3 are on, as a result of which the first terminal 51 and the second terminal 52 on the primary side of the transformer 50 are electrically connected to one another. On the secondary side, all four switching elements S5 to S8 of the second full-bridge 40 are actively controlled and therefore on. Therefore, on the secondary side, the terminals 53, 54 of the secondary terminal of the transformer are electrically connected to one another, and the terminals 21, 22 on the secondary side of the DC-DC converter 1 are likewise electrically connected to one another, via the series inductance 60.

[0034] Between times t2 and t3, the transformer current decreases further owing to the resistances in the transformer 50 and the switching elements in the full-bridges. This results in the current through the secondary-side inductance 60 being conducted uniformly by all four secondary-side switching elements S5 to S8 in the second full-bridge 40. Correspondingly, owing to the reduction in the reactive current in this phase, the losses in all switches and in the transformer 50 can be reduced.

[0035] At time t3, the switching elements S5 and S8 in the second full-bridge 40 are opened. The current through the secondary-side inductance 60 therefore needs to be completely conducted by the transformer 50 again. Owing to the leakage inductance of the transformer 50, therefore, there is an overvoltage across the secondary-side switches at time t3. Owing to the typically low leakage inductance of the transformers in the phase-shifted full-bridge DC-DC converters and snubber networks which may be present across the secondary-side switches, the resultant overvoltage does not impair the operation up to high power transmissions in the reverse direction. Up to time t4, the current is conducted in “freewheeling” fashion via the first and third switching elements S1 and S3, with the result that, furthermore, at least approximately a voltage of approximately 0 volt is present across the secondary-side switches. Since the losses in the switches and the transformer 50 are increased markedly between t3 and t4 without any power transmission, this time period is preferably selected to be as short as possible.

[0036] At time t4, the first switching element S1 switches off, and the second switching element S2 is switched on. The previously described switching operation takes place in turn with soft-switching owing to the negative transformer current, with the result that likewise soft switching-on is achieved for all primary-side switching operations. At time t4, the second half of a period begins with the power transmission from the secondary side to the primary side, which second half of the period runs symmetrically and analogously to the above-described first half of the period.

[0037] FIG. 3 shows a graph for a switching sequence for controlling a DC-DC converter for an energy transmission from the secondary side to the primary side in accordance with a further exemplary embodiment. The switching sequence in accordance with this exemplary embodiment differs from the previously described switching sequence in particular in that, between times t2 and t3 (and similarly in the second half of the period), in each case only three switching elements of the four switching elements S5 to S8 of the second full-bridge 40 are on. One of the switching elements S5 to S8 of the secondary-side full-bridge 40 is in this case open. In FIG. 3, this is, for example, the switching element S5. Furthermore, the statements made previously in connection with FIG. 2 apply.

[0038] FIG. 4 shows a flowchart, as forms the basis of a method 100 for controlling a DC-DC converter 1 in accordance with one embodiment. In particular, the method can comprise the sequences described previously in connection with FIG. 1 to FIG. 3.

[0039] At time t0, in a step 110, a first terminal 53 of the secondary side of the transformer 50 can be connected to a first terminal 22 of the secondary side of the DC-DC converter. Furthermore, a second terminal 54 of the secondary side of the transformer 50 is connected to a second terminal 22 of the secondary side of the DC-DC converter 1. Furthermore, a first terminal 51 of the primary side of the transformer 50 is connected to a first terminal 11 of the primary side of the DC-DC converter 1, and a second terminal 52 of the primary side of the transformer 50 is connected to a second terminal 12 of the primary side of the DC-DC converter 1.

[0040] At time t1, in a second step 120, the first terminal 53 of the secondary side of the transformer 50, the second terminal 54 of the secondary side of the transformer 50, the first terminal 21 of the secondary side of the DC-DC converter and the second terminal 22 of the secondary side of the DC-DC converter are connected to one another. In other words, therefore, an electrical connection of the secondary-side terminals 53, 54 of the transformer 50 and, if appropriate via the series inductance 60, the secondary-side DC-DC converter terminals 21, 22 takes place.

[0041] Thereupon, at time t2, in step 130, a disconnection of the connection between the second terminal 52 of the primary side of the transformer 50 and the second terminal 12 of the primary side of the DC-DC converter 1 takes place. Furthermore, in step 130, a connection of the second terminal 52 of the primary side of the transformer 50 to the first terminal 11 of the primary side of the DC-DC converter 1 takes place.

[0042] Finally, at time t3, in step 140, the disconnection of the connection between the first terminal 53 of the secondary side of the transformer 50 and the second terminal 54 of the secondary side of the transformer 50 and the disconnection of the connection between the first terminal 21 of the secondary side of the DC-DC converter 1 and the second terminal 22 of the secondary side of the DC-DC converter 1 take place. In addition, in this step 140, a connection between the second terminal 22 of the secondary side of the DC-DC converter 1 and the first terminal 53 of the secondary side of the transformer 50 takes place.

[0043] Owing to steps 110 to 140, therefore, the first half of a power transmission from the secondary side to the primary side of the DC-DC converter 1 takes place. Thereupon, owing to steps 150 to 180, the second half of a period for power transmission from the secondary side to the primary side can be implemented. In this case, steps 150 to 180 follow a similar switching pattern to steps 110 to 140, with the reverse current flow through the transformer 50.

[0044] By way of summary, the present invention relates to power transmission in a DC-DC converter, in particular a phase-shifted full-bridge DC-DC converter, from the secondary side to the primary side. In this case, in particular an additional switching state is provided, which can reduce the power losses of the switching elements in the DC-DC converter.