The present invention relates to a charger.
Various insulated single-phase AC/DC converters have been studied as battery chargers for electric vehicles. In general, a circuit configuration including a diode rectifier with a power factor correction (PFC) circuit, a large-capacity capacitor in the DC link section, and a high-frequency isolated DC/DC converter is used as a charger for electric vehicles. The large-capacity capacitor in the DC link section is required to have a capacity sufficient to absorb power ripple from the single-phase AC power supply, and with such a circuit configuration, it has been difficult to reduce the size.
As a compact charger capable of absorbing the ripple of the power, Non-Patent Document 1 discloses a charging circuit including a Dual-Active-Bridge (DAB) converter with an active buffer for absorbing the ripple of the power and also discloses control thereof.
Non-Patent Document 1: Shohei Komeda, Yoshiya Ohnuma, “Dual Active Bridge AC-DC Converter with an Active Energy Buffer”, Papers of Technical Meeting on Semiconductor Power Converter, 2021, SPC-21-003, pp. 13-18
A DAB converter contains full-bridge circuits on both the primary and secondary sides. In general, circuits containing full bridge circuits have a dead time during which all switches in a leg containing a switch that is to be switched are in the OFF state before switching from OFF to ON. However, in the control of the charging circuit disclosed in Non-Patent Document 1, if a dead time is provided for all the timings in which the switches of the DAB converter are switched from OFF to ON, distortion occurs in the reactor current and the output current, and the measured value of transmission power becomes smaller than the command value, resulting in a drop in efficiency.
Accordingly, it is an object of the present invention to provide a compact and highly efficient charger capable of absorbing the ripple of the power.
In order to solve the above problems, a charger according to one embodiment of the present invention includes: a rectifier including two input terminals for connection to an alternating-current power supply, a cathode terminal, and an anode terminal; a DC/DC converter including a first terminal connected to the cathode terminal of the rectifier via a first line, a second terminal connected to the anode terminal of the rectifier via a second line, and two output terminals for connection to a battery; a power ripple absorption circuit including a first diode, a second diode, a third diode, an inductor, a capacitor, a first switch, and a second switch; and a control unit configured to control switching of switches of the DC/DC converter, the first switch, and the second switch, wherein the first diode is connected between the inductor of the power ripple absorption circuit and one of the input terminals of the rectifier, the second diode is connected between the inductor and the other of the input terminals of the rectifier, the capacitor and the first switch are connected in series between the first line and the second line, the capacitor being provided on a side of the second line, the third diode is connected between: a line connecting the capacitor and the first switch; and the inductor of the power ripple absorption circuit, the second switch is connected between: the second line; and a line connecting the inductor of the power ripple absorption circuit and the third diode, control of the switching of the DC/DC converter by the control unit includes a first mode in which all of the switches of the DC/DC converter are OFF and a plurality of second modes in which at least one of the switches of the DC/DC converter is ON, and when switching from the first mode to one of the plurality of second modes, the control unit does not provide a dead time between the first mode and the one of the plurality of second modes.
According to the present invention, a compact and highly efficient charger capable of absorbing the ripple of the power can be provided.
The rectifier 110 includes: a cathode terminal 111 and an anode terminal 112 connected to the DC/DC converter 120; and two input terminals 113 for connection to the alternating-current power supply 200. For example, as illustrated in
The DC/DC converter 120 is, for example, a dual active bridge (DAB) converter. The DC/DC converter 120 includes a first terminal 121 connected to the cathode terminal 111 of the rectifier 110, a second terminal 122 connected to the anode terminal 112 of the rectifier 110, a third terminal 123 connected to the positive electrode of the battery 300, and a fourth terminal 124 connected to the negative electrode of the battery 300. The DC/DC converter 120 includes: a transformer Tr; a full-bridge circuit including four switches, i.e., a first switch S21, a second switch S22, a third switch S23, and a fourth switch S24, on the input side (primary side); and a full-bridge circuit including four switches, i.e., a fifth switch S25, a sixth switch S26, a seventh switch S27, and an eighth switch S28, on the output side (secondary side). The transformer Tr is interposed between the full-bridge circuit on the input side (primary side) and the full-bridge circuit on the output side (secondary side). Each of the eight the switches S21 to S28 is, for example, an N-channel power metal-oxide-semiconductor field-effect transistor (MOSFET) with an opposite polarity diode (a body diode). In this case, the N-channel power MOSFET may have a snubber capacitor as shown in
The full-bridge circuit on the primary side of the DC/DC converter 120 includes two legs (i.e., a leg including the first switch S21 and the second switch 22 and a leg including the third switch S23 and the fourth switch S24) connected between the first terminal 121 and the second terminal 122, and the full-bridge circuit on the secondary side of the DC/DC converter 120 includes two legs (i.e., a leg including the fifth switch S25 and the sixth switch 26 and a leg including the seventh switch S27 and the eighth switch S28) connected between the third terminal 123 and the fourth terminal 124.
The DC/DC converter 120 has an inductor L on the primary side of the transformer Tr. The inductor L has, for example, a leakage inductor of the transformer Tr.
Also, a direct-current capacitor Cdc is connected between the third terminal 123 and the fourth terminal 124 of the DC/DC converter 120. An inductor Ldc may be connected between the third terminal 123 of the DC/DC converter 120 and the positive electrode of the battery 300.
The power ripple absorption circuit 130 includes a first diode D31, a second diode D32, a third diode D33, an inductor Lb, a buffer capacitor Cbuf, a first switch S31, and a second switch S32.
The first diode D31 of the power ripple absorption circuit 130 is connected between the inductor Lb of the power ripple absorption circuit 130 and one of the two input terminals 113 of the rectifier 110, and the second diode D32 of the power ripple absorption circuit 130 is connected between the inductor Lb of the power ripple absorption circuit 130 and the other of the two input terminals 113 of the rectifier 110. In this case, the first diode D31 and the second diode D32 of the power ripple absorption circuit 130 are connected between the inductor Lb of the power ripple absorption circuit 130 and the input terminals 113 of the rectifier 110, in such a manner that the forward direction of the first diode D31 and the second diode D32 is the direction from the input terminal 113 of the rectifier 110 to the inductor Lb. Accordingly, even though the alternating-current power supply 200 is connected to the input terminals 113 of the rectifier 110, the inductor Lb of the power ripple absorption circuit 130 receives direct current.
The buffer capacitor Cbuf and the first switch S31 of the power ripple absorption circuit 130 are connected in series between: a first line LH connecting the cathode terminal 111 of the rectifier 110 and the first terminal 121 of the DC/DC converter 120; and a second line LL connecting the anode terminal 112 of the rectifier 110 and the second terminal 122 of the DC/DC converter 120. The buffer capacitor Cbuf is provided on the side of the second line LL, and the first switch 31 is provided on the side of the first line LH. The first switch S31 is, for example, an N-channel power metal-oxide-semiconductor field-effect transistor (MOSFET) with an opposite polarity diode (body diode). In this case, the source of the N-channel power MOSFET may be connected to the first line LH, and the drain of the N-channel power MOSFET may be connected to the buffer capacitor.
The third diode D33 of the power ripple absorption circuit 130 is connected between: a line connecting the buffer capacitor Cbuf and the first switch S31 of the power ripple absorption circuit 130; and the inductor Lb of the power ripple absorption circuit 130, in such a manner that the forward direction of the third diode D33 is the direction from the inductor Lb to this line.
The second switch S32 of the power ripple absorption circuit 130 is connected between the second line LL and a line connecting the inductor Lb and the third diode D33 of the power ripple absorption circuit 130. The second switch S32 is, for example, an N-channel power metal-oxide-semiconductor field-effect transistor (MOSFET) with an opposite polarity diode (body diode). In this case, the drain of the N-channel power MOSFET may be connected to a line connecting the inductor Lb and the third diode D33 of the power ripple absorption circuit 130, and the source of the N-channel power MOSFET may be connected to the second line LL.
The control unit 140 controls switching of the switches S21 to S28 of the DC/DC converter 120 and the switches S31, S32 of the power ripple absorption circuit 130.
Because the power ripple absorption circuit 130 includes the first diode D31, the second diode D32, the third diode D33, the inductor Lb, the buffer capacitor Cbuf, and the second switch S32, the power ripple absorption circuit 130 can function as a power factor correction (PFC) circuit. For this reason, in the present embodiment, control can be performed so that a sine wave voltage vs and a sine wave current is as explained below are input from the alternating-current power supply 200 to the charger 100.
[Math 1]
νs(t)=√{square root over (2)}Vssinωst
i
s(t)=√{square root over (2)}Issinωst
Vs denotes the effective value of the power supply voltage, and Is denotes the effective value of the power supply current.
In this case, as indicated below, the instantaneous power ps that is output from the alternating-current power supply 200 is a sum of an average power P (=VsIs) and a ripple portion prip (t) (=−VsIscos2ωst), and as indicated by a solid line in
[Math 2]
p
s(t)=νsis=VsIs(1−cos2ωst)=P+prip(t)
Accordingly, the control unit 140 controls the switches S21 to S28 of the DC/DC converter 120 and the switches S31, S32 of the power ripple absorption circuit 130, so that the power ripple absorption circuit 130 absorbs the ripple of the power from the alternating-current power supply to make the power provided to the DC/DC converter 120 constant.
In this case, the charger 100 according to the present embodiment changes the control between when the instantaneous power ps that is output from the alternating-current power supply 200 is higher than the average power P (ps>P) and when the instantaneous power ps that is output from the alternating-current power supply 200 is lower than the average power P (ps<P).
When the instantaneous power ps that is output from the alternating-current power supply 200 is higher than the average power P (ps>P), switching of the eight switches S21 to S28 of the DC/DC converter 120 and the two switches S31, S32 of the power ripple absorption circuit 130 is controlled, so that the ripple portion prip of the instantaneous power ps that is output from the alternating-current power supply 200 is charged to the buffer capacitor Cbuf via the inductor Lb of the power ripple absorption circuit 130, and accordingly, only the average power P of the power that is output from the alternating-current power supply is provided to the DC/DC converter 120. In other words, in the present embodiment, the period in which the instantaneous power ps that is output from the alternating-current power supply 200 is higher than the average power P is a period (charge period) in which the buffer capacitor Cbuf is charged, and in which the instantaneous power pC that is output from the buffer capacitor Cbuf is negative as indicated by a long dashed short dashed line in
On the other hand, when the instantaneous power ps that is output from the alternating-current power supply 200 is lower than the average power P (ps<P), the second switch S32 of the power ripple absorption circuit 130 keeps the OFF state and controls switching of the eight switches S21 to S28 of the DC/DC converter 120 and the first switch S31 of the power ripple absorption circuit 130 to actively discharge the buffer capacitor Cbuf via the first switch S31, so that the ripple portion prip that is the difference between the average power P and the instantaneous power ps that is output from the alternating-current power supply 200 is compensated for, and accordingly, the average power P is provided to the DC/DC converter 120. In other words, in the present embodiment, the period in which the instantaneous power ps that is output from the alternating-current power supply 200 is lower than the average power P is a period (discharge period) in which the buffer capacitor Cbuf is discharged, and in which the instantaneous power pC that is output from the buffer capacitor Cbuf is positive as indicated by the long dashed short dashed line in
Therefore, in the present embodiment, the control unit 140 controls switching of the switches S21 to S28 of the DC/DC converter 120 and the switches S31 to S32 of the power ripple absorption circuit 130, so that the sum of the instantaneous power ps that is output from the alternating-current power supply 200 and the instantaneous power pC that is output from the buffer capacitor Cbuf becomes constant.
In this manner, in the present embodiment, the buffer capacitor Cbuf is actively discharged in the discharge period. For this reason, in the present embodiment, the mount of power accumulated in the buffer capacitor Cbuf (i.e., the capacity of the buffer capacitor Cbuf) can be reduced, and the size of the buffer capacitor Cbuf can be reduced.
Furthermore, in the present embodiment, the second switch S32 is activated only in the charge period. For this reason, in the present embodiment, the mount of power accumulated in the inductor Lb (i.e., the inductance of the inductor Lb) can be reduced, and the size of the inductor Lb can be reduced.
Furthermore, in the present embodiment, the power provided to the DC/DC converter 120 does not have ripple. For this reason, in the present embodiment, the transformer Tr of the DC/DC converter 120 and the direct-current capacitor Cdc can be reduced in size.
As described above, in the present embodiment, the sizes of passive devices such as capacitors, inductors, and transformers can be reduced. Therefore, in the present embodiment, the compact and highly efficient charger capable of absorbing the ripple of the power can be provided.
The control unit 140 controls switching of the switches S21 to S28 of the DC/DC converter 120 and the first switch S31 of the power ripple absorption circuit 130 according to seven modes, so that an operation waveform iL, of the inductor L of the DC/DC converter 120 attains an operation waveform that can be approximated by square waveforms.
In this case, tcn (n=1 to 7) denotes a time at which the mode is switched to mode n.
In the present embodiment, in order to actively discharge the buffer capacitor Cbuf when the first switch S31 of the power ripple absorption circuit 130 is in the ON state, the control unit 140 performs control so that the voltage vC applied to the buffer capacitor Cbuf is always greater than the instantaneous voltage vrec that is output from the rectifier 110. Accordingly, in the present embodiment, the voltage vC applied to the buffer capacitor Cbuf has a value different from the instantaneous voltage vrec of the rectifier 110, and the inclination of the operation waveform iL is different between mode 2 and mode 3. Likewise, the inclination of the operation waveform iL is different between mode 6 and mode 7. Therefore, in the present embodiment, as illustrated in
In the operation waveform iL as illustrated in
In the equivalent square waveform iL′, a period at t0≤t<t1, tS1≤t<t4, t5≤t<t6, tS2≤t<t9 is defined as a reactive current period Tq, a period at t1≤t<t2, t7≤t<t8 is defined as a buffer capacitor discharge current period TC, a period at t2≤t<t3, t6≤t<t7 is defined as a power supply current period Trec, a period at t3≤t<tS1, t8≤t<ts2 is defined as a current balance period Tb, and a period at t4≤t<t5, t9≤t<t10 is defined as a zero-current period T0. In this case, the duty cycle of each period in the switching period TSW is as follows.
The duty cycle of each period can be obtained by giving irec, vC, Vdc, IL′ as command values. The control law for the operation waveform iL of
According to the above-described control, in order to operate the charger 100, all of the duty cycles of the above expression (2) are required to be positive. During the buck operation (i.e., VS>Vdc), all of the duty cycles of the above expression (2) are positive, but during the boost operation (i.e., VS<Vdc), the duty cycle Db of the current balance period Tb and the duty cycle DC of the buffer capacitor discharge current period TC may be negative, as illustrated in
[Math 7]
(νrec−Vdc)rec+(νC−Vdc)C<0 (3)
When the duty cycle DC of the buffer capacitor discharge current period TC is negative, the following expression holds.
[Math 8]
(νrec−Vdc)rec+(νC+Vdc)C<0 (4)
Therefore, in the present embodiment, when the duty cycle Db of the current balance period Tb becomes negative (i.e., the above expression (3) becomes satisfied), the switching control is changed, and when the duty cycle DC of the buffer capacitor discharge current period TC becomes negative (i.e., the above expression (4) becomes satisfied), the switching control is further changed. Hereinafter, the control that is performed when both the above expression (3) and (4) are not satisfied, i.e., the control explained above, is referred to as a buck sequence, the control that is performed when the above expression (3) is satisfied but the above expression (4) is not satisfied is referred to as a boost sequence I, and the control that is performed when both the above expression (3) and (4) are satisfied is referred to as a boost sequence II.
In the operation waveform iL as illustrated in
In the equivalent square waveform iL′, a period at t0≤t<tS1, t3≤t<t4, t5≤t<tS2, t8≤t<t9 is defined as a reactive current period Tq, a period at t1≤t<t2, t7≤t<t8 is defined as a buffer capacitor discharge current period TC, a period at t2≤t<t3, t6≤t<t7 is defined as a power supply current period Trec, a period at tS1≤t<t1, tS2≤t<t6 is defined as a current balance period Tb, and a period at t4≤t<t5, t9≤t<t10 is defined as a zero-current period T0. In this case, the duty cycle of each period in the switching period TSW is as follows.
For the boost sequence I, the duty cycle of each period can also be obtained by giving irec, iC, vC, Vdc, IL′, as command values. By using the duty cycle of each period thus obtained, the control law for the operation waveform iL (boost sequence I) of
Furthermore, in the present embodiment, when both of the above expressions (3) and (4) are satisfied, switching of the switches S21 to S28 of the DC/DC converter 120 and the first switch S31 of the power ripple absorption circuit 130 is controlled according to nine modes as illustrated in
Then, in the operation waveform iL as illustrated in
In the equivalent square waveform iL′, a period at t0≤t<t1, t4≤t<t5, t6≤t<t7, t1≤t<t11 is defined as a reactive current period Tq, a period at t2≤t<t3, t9≤t<t10 is defined as a buffer capacitor discharge current period TC, a period at t3≤t<t4, t8≤t<t9 is defined as a power supply current period Trec, a period at t1≤t<t2, t7≤t<t8 is defined as a power suppply current period Trec, a period at t1≤t<t2, t7≤t<t8 is defined as a current balance period Tb, and a period at t5≤t<t6, t11≤t<t12 is defined as a zero-current period T0. In this case, the duty cycle of each period in the switching period TSW is as follows
For the boost sequence II, the duty cycle of each period can also be obtained by giving irec, iC, vC, Vdc, IL′, as command values. By using the duty cycle of each period thus obtained, the control law for the operation waveform iL (boost sequence II) of
The DAB converter includes full-bridge circuits on both the primary side and the secondary side. In general, in a circuit including a full-bridge circuit, when a switch is switched from OFF to ON, a dead time in which all the switches in the leg including the switch that is to be switched are turned OFF is provided in order to prevent all the switches in the same leg from turning ON and shorting the circuit. Therefore, with the charger 100 according to the present embodiment, it is considered to provide, for all of the timings at which the switches S21 to S28 of the DC/DC converter 120 are switched from OFF to ON, a dead time in which all the switches in the leg including the switch that is to be switched are turned OFF.
Therefore, during the buck sequence, as illustrated by a solid line in
As described above, when the dead time Td is provided for all the timings at which the switches S21 to S28 of the DC/DC converter 120 are switched from OFF to ON, the mode 1 starts at t=t0+Td. In the mode 5 that is immediately before the mode 1, the value of the current iL of the inductor L is zero. Therefore, when the start of the mode 1 delays, the current starts to flow to the inductor L with a delay. As a result, as described above, when the dead time Td is provided for all the timings at which the switches S21 to S28 of the DC/DC converter 120 are switched from OFF to ON, the value of the current iL of the inductor L at the end of the mode 1 (t=t1) as indicated by the solid line in
This value is smaller than the value at t=t1 of the operation waveform iL as illustrated in
Therefore, in a case where the dead time Td is provided for all the timings at which the switches S21 to S28 of the DC/DC converter 120 are switched from OFF to ON, the waveform of the current iL of the inductor L (waveform as illustrated by a solid line in
Therefore, in the present embodiment, as indicated by a solid line in
As a result, as illustrated in
Accordingly, the distortion of the waveform of the current iL of the inductor L is eliminated, and the decrease in the transmission power is also eliminated. Furthermore, as illustrated in
As explained above, in the present embodiment, the dead time is set so that distortion does not occur in the reactor current and the output current and the transmission power does not decrease. Therefore, in the present embodiment, the compact and highly efficient charger capable of absorbing the ripple of the power can be provided.
In the above explanation, the setting of the dead time has been explained with reference to the example of the buck sequence, but the dead time can be set likewise for the boost sequence I and the boost sequence II, so that distortion does not occur in the reactor current and the output current and the transmission power does not decrease.
In a manner similar to the buck sequence (the waveform of
Unlike the buck sequence (the waveform of
The control unit 140 uses a triangle wave comparison method to generate a control signal for controlling switching of, for example, the switches S21 to S28 of the DC/DC converter 120 and the switch S31 of the power ripple absorption circuit 130. In the present embodiment, six modulation waves m1 to m6 are used. In the buck sequence, the control unit 140 sets the modulation waves m1 to m6 such that in the increasing period at the triangle wave, when the modulation wave m1 crosses the triangle wave, the zero-current period T0 ends and the reactive current period Tq starts; when the modulation wave m2 crosses the triangle wave, the reactive current period Tq ends and the buffer capacitor discharge current period TC starts; when the modulation wave m3 crosses the triangle wave, the buffer capacitor discharge current period TC ends and the power supply current period Trec starts; when the modulation wave m4 crosses the triangle wave, the power supply current period Trec ends and the current balance period Tb starts; when the modulation wave m5 crosses the triangle wave, the current balance period Tb ends and the reactive current period Tq starts; and when the modulation wave m6 crosses the triangle wave, the reactive current period Tq ends and the zero-current period T0 starts, and such that in the decreasing period at the triangle wave, when the modulation wave m6 crosses the triangle wave, the zero-current period T0 ends and the reactive current period Tq starts; when the modulation wave m5 crosses the triangle wave, the reactive current period Tq ends and the power supply current period Trec starts; when the modulation wave m4 crosses the triangle wave, the power supply current period Trec ends and the buffer capacitor discharge current period TC starts; when the modulation wave m3 crosses the triangle wave, the buffer capacitor discharge current period TC ends and the current balance period Tb starts; when the modulation wave m2 crosses the triangle wave, the current balance period Tb ends and the reactive current period Tq starts; and when the modulation wave m1 crosses the triangle wave, the reactive current period Tq ends and the zero-current period T0 starts.
In the decreasing period at the triangle wave (t4+T0/2≤t<t9+T0/2), the inclination of the triangle wave is −2/Tsw, and accordingly, the modulation waves m1 to m6 are set as follows.
In the waveform without the dead time at t=t0, t5 (the waveform of
and in the decreasing period at the triangle wave, the modulation waves m6, m5 are set as follows, so that the waveform without the dead time at t=t0, t5 (the waveform of
However, as indicated by the solid line of
[Math 20]
D
0≥2Dtd (8)
The value of the duty cycle D0 of the zero-current period T0 can be adjusted by appropriately giving the maximum value of the voltage vC applied to the buffer capacitor Cbuf, but in order to satisfy the above expression (8), it is necessary to increase the maximum value of the voltage vC applied to the buffer capacitor Cbuf. Specifically, when the triangle wave illustrated in
Therefore, in the present embodiment, as illustrated in
In the decreasing period at the triangle wave (t4+T0/2≤t<t9+T0/2), the modulation waves m1 to m6 are set as follows.
Furthermore, in order for the modulation wave m1 to cross the triangle wave, it is necessary to satisfy 0≤m1≤1. Therefore, it is necessary to satisfy the following expression (9).
[Math 23]
D
0
≤D
td (9)
In this manner, the triangle wave is set to attain the maximum value or the minimum value at the start of the first mode (at the start of the mode 5), so that, as illustrated in
In the above explanation, the settings of the triangle wave and the modulation wave have been explained with reference to the example of the buck sequence, but the triangle wave and the modulation wave can be set likewise for the boost sequence I and the boost sequence II, so that distortion does not occur in the output current and it is not necessary to increase the maximum value of the voltage applied to the buffer capacitor.
In a manner similar to the buck sequence (the waveform of
The position of the current balance period Tb in the boost sequence I (the waveform of
The present invention has been hereinabove described according to the preferred embodiment of the present invention. Although the present invention has been described with reference to the particular embodiment, various modifications and changes can be made to the embodiment without departing from the spirit and scope of the invention as set forth in the claims.
Number | Date | Country | Kind |
---|---|---|---|
2022-130165 | Aug 2022 | JP | national |