The present disclosure relates to the field of electrical power conversion. In particular, the present disclosure relates to an electrical converter for converting between three phase AC and DC with galvanic isolation.
A typical three-phase galvanically isolated power supply, such as those used for charging battery driven electrical vehicles, comprises a three-phase rectifier with power factor correction (PFC) unit coupled to an isolated DC/DC converter unit. The isolated DC/DC converter unit converts power between the DC output of the three-phase rectifier unit, having typical voltage levels in the range of 700-800V, and the battery of the vehicle, having typical voltage levels in the range of 250-450V. In such cases where the input voltage (e.g. 700-800V) of the DC/DC converter unit is significantly higher than the output voltage (e.g. 250-450V) of the DC/DC converter unit, the isolated DC/DC converter unit often comprises two series-in, parallel-out coupled isolated DC/DC converters.
Barbosa P. et al., “Analysis and evaluation of the two-switch three-level boost rectifier”, 32nd annual IEEE Power Electronics Specialists Conference 2001 Conference proceedings, vol. 3, 17 Jun. 2001, pp. 1659-1664, describes in relation to
One drawback associated with the above power supplies is that they tend to become bulky and expensive.
Silva M. et al., “Isolated Swiss-Forward Three-Phase Rectifier with Resonant Reset”, IEEE Transactions on Power Electronics, Vol. 31, No. 7, 2016, pp. 4795-4808 describe a modified Swiss-type rectifier. PFC operation of the Swiss Rectifier is basically achieved by a combination of two stacked DC/DC buck converters and an active selector circuit comprising three bidirectional switches connected to the common node of the DC/DC buck converters in order to allow for active third-harmonic current injection. In their modified rectifier, the two DC/DC buck converters are replaced by two isolated DC/DC converters. This obviates the need of providing a secondary isolated stage. One drawback of the above converter is that the input voltage applied to the isolated DC/DC converters goes to zero at the crossings of the AC input phase voltages, resulting in poor controllability of the isolated DC/DC converters at these crossings leading to higher total harmonic distortion of the AC input currents. Also the isolated DC/DC converters experience a wide input voltage range resulting in an inefficient operation of the isolated DC/DC converters, requiring over dimensioning the isolated DC/DC converters.
There is a need in the art to provide an improved galvanically isolated three-phase AC/DC power supply. In particular, it is an object of the present disclosure to provide such power supplies which are more compact and more economical. It is an object to provide such power supplies which have similar or even improved performance characteristics over prior art power supplies of the above kind.
According to the present disclosure, there is therefore provided an electrical converter for converting an AC signal having at least three phases into a galvanically isolated DC signal or vice versa, as set out in the appended claims.
An electrical converter according to the present disclosure comprises (at least) three phase terminals, and two DC terminals, a first converter stage, a second converter stage and a third converter stage. The first converter stage comprises conversion circuitry configured for converting between the three phase voltages provided at the three phase terminals and a first signal provided at a first intermediate node and a second intermediate node. The conversion circuitry can be a bridge converter, in particular comprising a bridge leg for each of the at least three phase terminals. The first converter stage further comprises a phase selector comprising first active switches configured to selectively connect the three phase terminals to a third intermediate node.
The second converter stage is configured for converting between a second signal at a fourth intermediate node and a fifth intermediate node and a third signal at a sixth intermediate node and a seventh intermediate node. The second converter stage comprises or consists of a boost circuit, comprised of a first boost circuit and a second boost circuit series stacked between the sixth and seventh intermediate node.
A link, in particular a DC-link, connects the first intermediate node to the fourth intermediate node, and the second intermediate node to the fifth intermediate node. The link can comprise a differential mode filter, particularly operably coupled to the second converter stage.
The third converter stage comprises or consists of a galvanically isolated DC/DC converter stage comprising a first side and a second side galvanically isolated from each other. The first side is connected to the sixth intermediate node, a first common node and the seventh intermediate node. The DC terminals are connected to the second side of the DC/DC converter stage. The first common node is operably connected to the third intermediate node and the DC/DC converter stage is configured to be operated such that a difference of a first current applied to the DC/DC converter at the sixth intermediate node and a second current applied to the DC/DC converter at the seventh intermediate node is provided at the third intermediate node. The DC/DC converter stage can be built as a multi-port DC/DC converter, having three ports at the first side, or alternatively as two DC/DC converters wherein the first sides are stacked between the sixth and seventh intermediate nodes and having as common node the first common node.
The first and second boost circuits have a second common node. According to one advantageous aspect of the present disclosure, the first common node (of the third converter stage) and the second common node (of the second converter stage) are not connected, i.e. they are free from a direct or equipotential link between the two nodes. Likewise, the second common node is advantageously not connected to the third intermediate node (i.e. not connected through a direct or equipotential link or connection). However, the first common node and the third intermediate node are advantageously connected (i.e. through a direct or equipotential link).
One advantage of the electrical converter according to the present disclosure is that the isolated DC/DC converter stage acts as a current injection circuit, and hence no additional third harmonic current injection circuit is necessary to obtain sinusoidal mains currents with low total harmonic distortion and/or unity power factor. Nevertheless, by operating the DC/DC (third) converter stage as a third harmonic current injection circuit, it is advantageously obtained that the voltages at the first side of the DC/DC converter stage (between the sixth intermediate node and the first common node and between the first common node and the seventh intermediate node) remain positive and different from zero, in particular at the crossings of the AC phase voltages. This is made possible by separating the first common node from the second common node and results in better controllability of the third converter stage. Furthermore, electrical energy storage elements required for the current injection circuit to operate can be dispensed with, since they are taken over by components already present in the isolated DC/DC converter stage. Electrical converters according to the present disclosure hence are more compact, require less components and therefore are more economical.
According to a second aspect of the present disclosure, there is provided a battery charging system, such as for charging the battery of an electric vehicle, or an electric motor drive system, comprising a power supply, the power supply comprising the electrical converter as described herein.
Aspects of the present disclosure will now be described in more detail with reference to the appended drawings, wherein same reference numerals illustrate same features and wherein:
Referring to
The electrical converter 100 is an AC-to-DC converter that has three phase input terminals A, B, C which are connected to a three-phase voltage of a three-phase AC grid 21, and two DC terminals P, N which for example may be connected to a DC load 22, such as a high voltage (e.g. 250-450V) battery of an electric car.
The first converter stage 11 comprises three phase nodes a, b, c that are connected to the three phase input terminals A, B, C, and three output nodes T, I, B. These output nodes may be seen as an upper intermediate node T, a lower intermediate node B, and a middle intermediate node I.
The first converter stage 11 comprises a conversion circuitry 24 for conversion between a three-phase AC signal with three phase voltages provided at the three phase nodes a, b, c and an intermediate (DC) signal between the upper intermediate node T and the lower intermediate node B. When the conversion is from AC to DC, the conversion circuitry 24 functions as a rectifier, and when the conversion is from DC to AC, the conversion circuitry functions as an inverter. The conversion circuitry 24 advantageously comprises a three-phase bridge circuitry consisting of three bridge legs 16, 17, 18 wherein each bridge leg can comprise two active (bidirectional) or passive semiconductor switching devices connected in the form of a half bridge configuration. In the example of
The first converter stage 11 further comprises a phase selector 25 comprising three voltage-bidirectional semiconductor switching devices (SS,a, SS,b, and SS,c) allowing for bidirectional interruption of electric current and bidirectional blocking of voltage. Each of these current-bidirectional switching devices can comprise two anti-series connected active semiconductor switching devices.
Each active semiconductor switching device of the bridge circuitry 24 and/or the phase selector 25 advantageously comprises an anti-parallel diode. By way of example, Metal Oxide Field Effect Transistors (MOSFETs) are used for the active semiconductor switching devices, and each may include an internal anti-parallel body diode that may replace an external anti-parallel diode.
The second converter stage 12 comprises, or consists of, two stacked boost circuits 19, 20. Each boost circuit 19, 20 advantageously comprises a first boost switch (ST2 for the upper boost circuit 19 and SB1 for the lower boost circuit 20) and second boost switch (ST1 for the upper boost circuit 19 and SB2 for the lower boost circuit 20) connected in a half-bridge configuration. The first and second boost switches can be active, bidirectional switches, allowing bidirectional current flow, but current interruption in one sense only, e.g. MOSFET switching devices with anti-parallel (body) diode. Alternatively, the second boost switches ST1 and SB2 can be replaced by diodes. The middle node (switch node) r of the upper boost circuit 19 is connected to upper intermediate voltage node T via an upper boost inductor LT. The middle node (switch node) s of the lower boost circuit 20 is connected to lower intermediate voltage node B via a lower boost inductor LB. The first switches of the upper and lower boost circuits 19, 20 are connected to each other in common node m of the upper and lower boost circuits 19, 20. The second boost switch ST1 of the upper boost circuit 19 is connected between the middle node r and an upper boost node P′. The second boost switch SB2 of the lower boost circuit 20 is connected between the middle node s and a lower boost node N′.
The upper boost inductor LT and the lower boost inductor LB form the inductive part of the input filter 13. The capacitive part of the input filter 13 is advantageously formed by two high-frequency (HF) filter capacitors CT, CB each connected between the respective upper and lower intermediate node T, B, and a common node, which may be further connected to the common node m between the boost circuits 19 and 20. Generally, it is advantageous that the two capacitors CT, CB have substantially equal capacitance in order to symmetrically load the AC grid.
The output filter 15 comprises two series connected output filter capacitors C, advantageously of equal capacitance, connected across the outputs P′ and N′ of the upper and lower boost circuits 19, 20 respectively. P′ and N′ will hereinafter be referred to as upper and lower boost nodes, respectively. A midpoint node q between the output filter capacitors C is advantageously connected to the common node m between the upper and lower boost circuits 19, 20. It is alternatively possible to provide a single output filter capacitor connected across the upper and lower boost nodes P′ and N′.
The upper boost circuit 19 is connected between the upper boost node P′ and the common node m (advantageously in parallel with the upper output filter capacitor), and is arranged in a way that current can flow from the upper intermediate node T to the upper boost node P′ (or vice versa) via switch ST1 when switch ST2 is open (not conducting, off state), and current can flow from the upper intermediate node T to the common node m (or vice versa) via the switch ST2 when the switch ST2 is closed (conducting, on state). At least boost switch ST2 of the boost circuit 19 is an actively controlled semiconductor switching device, for example a MOSFET, which may be operated by pulse width modulation. In case the switch ST1 is replaced by a diode DT1, current can flow from the upper intermediate node T to the upper boost node P′ via diode DT1 when switch ST2 is open (not conducting, off state) but current cannot flow from the upper boost node P′ to the upper intermediate node T.
The lower boost circuit 20 is connected between the common node m and the lower boost node N′ (advantageously in parallel with the lower output filter capacitor), and is arranged in a way that current can flow from the lower boost node N′ to the lower intermediate node B (or vice versa) via the switch SB2 when the switch SB1 is open (not conducting, off state), and current can flow from the common node m to the lower intermediate node B (or vice versa) via the switch SB1 when the switch SB1 is closed (conducting, on state). At least boost switch SB1 of the boost circuit 20 is an actively controlled semiconductor switching device, for example a MOSFET, which may be operated by pulse width modulation. In case the switch SB2 is replaced by a diode DB2, current can flow from the lower boost node N′ to the lower intermediate node B via diode DB2 when switch SB1 is open (not conducting, off state) but current cannot flow from the lower intermediate node B to the lower boost node N′.
The electrical converter optionally comprises a neutral terminal (not shown) for connecting to the neutral conductor of the grid. The neutral terminal can be connected to the common node k of the high-frequency (HF) filter capacitors CT, CB and/or to the common node m of the first and second boost circuits 19, 20. Referring to
The third converter stage 14 is formed by two galvanically isolated DC/DC converters 141, 142 whose inputs are connected in series across the upper and lower boost nodes P′ and N′ and whose outputs are connected to the output terminals P, N of the converter 100, either through a parallel connection as shown in
Any suitable galvanically isolated DC/DC converter as known in the art can be used for converters 141 and 142. One possible DC/DC converter topology for converters 141 and 142 is represented in
The first side nodes F1, G1 are connected to nodes P′ and t respectively for the upper isolated DC/DC converter 141 and to nodes t and N′ respectively for the lower isolated DC/DC converter 142. The second side nodes F2, G2 are connected to the DC terminals P, N of the converter 100, either through a series or parallel connection between converters 141 and 142.
The topology of
Referring to
Further suitable topologies for DC/DC converters in the third converter stage 14 are described in Krismer Florian, Modeling and Optimization of Bidirectional Dual Active Bridge DC-DC Converter Topologies, Dissertation ETH Zürich No. 19177, 2010, available online:
https://www.pes-publications.ee.ethz.ch/uploads/tx_ethpublications/Krismer_2011_03_17_Modeling_and_Op timization_of_Bidirectional_Dual_Active_Bridge_DC-DC_Converter_Topologies.pdf
Referring again to
In addition, the control unit 30 advantageously controls the active switches of at least the first side 411, 421 of the isolated DC/DC converters 141, 142 or 140.
The electrical converter 100 basically combines a boost type three-phase rectifier formed by the first converter stage 11, input filter 13, second power (boost) stage 12 and output filter 15, with two series-in connected isolated DC/DC converters. According to the present disclosure, the isolated DC/DC converter stage together with the phase selector 25 act as a third-harmonic current injection circuit, obviating the need for an additional conventional buck-boost circuit and boost inductor, resulting in a more compact design.
When a three-phase AC grid 21 is connected to the input terminals A, B, C with AC grid phase voltages va, vb, vc (
Referring to
Referring to
Referring to
The input filter 13 in the DC-link between nodes T and B on the one hand, and nodes r and s on the other, can comprise only two inductors LT and LB operably coupled to the upper intermediate node T and lower intermediate node B respectively, without there being any inductor operably coupled to the middle intermediate node I. In other words, the current injection line between the middle intermediate node I and the common node t between the inputs of the isolated DC/DC converters can be free of inductive energy storage elements. Alternatively, a third inductor can be provided between nodes I and t.
Electrical converters according to the present disclosure are advantageously used for converting from three-phase AC to DC and/or vice versa. Particularly useful applications are in power supply units of battery chargers, in particular for charging electric batteries of electric (motor-driven) vehicles.
Referring to
Aspects of the present disclosure are set out in the following numbered clauses.
10. Electrical converter of any one of the preceding clauses, wherein the galvanically isolated DC/DC converter stage comprises a first galvanically isolated DC/DC converter (141) comprising a first side connected to the sixth intermediate node (P′) and the first common node (t) and a second galvanically isolated DC/DC converter (142) comprising a first side connected to the first common node (t) and the seventh intermediate node (N′), wherein the DC terminals (P, N) are connected to second sides of the first and second DC/DC converter.
Number | Date | Country | Kind |
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2025504 | May 2020 | NL | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/061592 | 5/3/2021 | WO |