The present disclosure relates to a multi-phase DC/DC converter. More particularly, the present disclosure relates to an isolated multi-phase DC/DC converter with a reduced quantity of blocking capacitors.
In general, the power supply industry continuously demands converters with high efficiency, high power density, and low cost in order to achieve less energy consumption, smaller installation space, and cost effectiveness. In addition, higher power processing is required in many newly developed applications, such as, electrical vehicles (EV) and data centers. By using higher power rated converters, charging time of EVs and the size of power racks in data centers can be significantly reduced.
Multi-phase converter topologies are commonly employed to increase processing power. In multi-phase converters, each phase delivers a portion of the total power. Since the current stress of each phase is only a fraction of the total current, the conduction loss as well as the temperature of components can be easily limited. In addition, the operation of each phase of the multi-phase converter can be interleaved, so that switching ripples of the phases can cancel each other and the filter size can be reduced significantly. Furthermore, multi-phase converters with multi-phase transformers can inherently achieve current sharing without any additional control. For these reasons, multi-phase DC/DC converters are attractive candidates in high power applications. See, for example, T. Jin and K. Smedley, “Multiphase LLC Series Resonant Converter for Microprocessor Voltage Regulation,” Conference Record of the 2006 Industry Applications Conference Forty-First IAS Annual Meeting, vol. 5, pp. 2136-2143, October 2006; and J. Jacobs, A. Averberg and R. De. Doncker, “A Novel Three-Phase DC/DC Converter for High-Power Applications,” 2004 35th Annual IEEE Power Electronics Specialists Conference, vol. 3, pp. 1861-1867, June 2004.
Although isolated multi-phase DC/DC converters show advantages in high power applications, it is still important to further improve efficiency, power density, and cost effectiveness.
The present disclosure provides an isolated multi-phase DC/DC (direct current/direct current) converter with a reduced number of blocking capacitors that prevent saturation of the transformer. By using the fact that the current in a phase is equal to the sum of the currents in the other phases of the transformer, the blocking capacitor of the phase can be eliminated, because the DC components of the other phases can be eliminated by their own blocking capacitors. The DC/DC converter of the present disclosure can achieve both cost effectiveness and higher power density, because one blocking capacitor bank at the primary side and one blocking capacitor bank at the secondary side can be eliminated in a multi-phase transformer.
In one aspect, the isolated multi-phase DC/DC converter comprises a multi-phase transformer having a primary circuit and a secondary circuit magnetically coupled to the primary circuit, the primary circuit having a first quantity of terminals, and the secondary circuit having a second quantity of terminals; a third quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the primary circuit; and a fourth quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the secondary circuit; wherein the third quantity is one less than the first quantity; and wherein the fourth quantity is one less than the second quantity.
In one embodiment, the converter further comprises a first inverter or a first rectifier electrically connected to the primary circuit of the multi-phase transformer; and a second inverter or a second rectifier electrically connected to the secondary circuit of the multi-phase transformer.
In one embodiment, the converter further comprises a primary voltage source electrically coupled to the first inverter or the first rectifier; and a secondary voltage source electrically coupled to the second inverter or the second rectifier.
In one embodiment, the first quantity is at least two and the third quantity is one less than the first quantity.
In one embodiment, the second quantity is at least two and the fourth quantity is one less than the second quantity.
In one embodiment, the primary circuit includes the first quantity of windings connected with each other in a Y-connection configuration or a Δ-connection configuration, and the secondary circuit includes the second quantity of windings connected with each other in a Y-connection configuration or a Δ-connection configuration.
In one embodiment, the primary and secondary circuits comprise one of Y-Y winding pairs, Y-Δ winding pairs, Δ-Y winding pairs, and Δ-Δ winding pairs.
In one embodiment, said first quantity of windings of the primary circuit and said second quantity of windings of the secondary circuit are magnetically coupled through a single magnetic core or a plurality of independent magnetic cores.
In another aspect, the present disclosure provides an electrical circuit for converting electrical power. The electrical circuit comprises a primary circuit; and a secondary circuit magnetically coupled to the primary circuit; wherein the primary circuit includes a plurality of terminals, each being electrically coupled to the primary circuit via a primary blocking capacitor, except that at most one of the terminals of the primary circuit is electrically coupled directly to the primary circuit without the primary blocking capacitor.
In one embodiment, the secondary circuit includes a plurality of terminals, each being electrically coupled to the secondary circuit via a secondary blocking capacitor, except that at most one of the terminals of the secondary circuit is electrically coupled directly to the secondary circuit without the secondary blocking capacitor.
In one embodiment, the primary circuit comprises a plurality of windings connected with each other in a Y-connection configuration or a Δ-connection configuration.
In one embodiment, the secondary circuit comprises a plurality of windings connected with each other in a Y-connection configuration or a Δ-connection configuration.
In one embodiment, the primary circuit and the secondary circuit are magnetically coupled through a single magnetic core or a plurality of independent magnetic cores.
In one embodiment, the primary circuit includes at least two terminals and wherein at most one of the at least two terminals of the primary circuit is electrically coupled directly to the primary circuit without the primary blocking capacitor, and each of the remaining terminals of the primary circuit is electrically coupled to the primary circuit via the primary blocking capacitor.
In one embodiment, the secondary circuit includes at least two terminals and wherein at most one of the at least two terminals of the secondary circuit is electrically coupled directly to the secondary circuit without the secondary blocking capacitor, and each of the remaining terminals of the secondary circuit is electrically coupled to the secondary circuit via the secondary blocking capacitor.
In still another aspect, the present disclosure provides a multi-phase transformer. The transformer comprises at least two primary windings electrically coupled to each other in a Y-connection configuration or a Δ-connection configuration; at least two primary terminals electrically coupled respectively to said at least two primary windings; and at least one primary blocking capacitor, each being electrically coupled in series between a respective one of said at least two primary terminals and a respective one of said at least two primary windings; wherein at most one of said at least two primary terminals is electrically coupled directly to a respective one of said at least two primary windings without the blocking capacitor.
In one embodiment, the multi-phase transformer further comprises at least two secondary windings electrically coupled to each other in a Y-connection configuration or a Δ-connection configuration; at least two secondary terminals electrically coupled respectively to said at least two secondary windings; and at least one secondary blocking capacitor, each being electrically coupled in series between a respective one of said at least two secondary terminals and a respective one of said at least two secondary windings; wherein at most one of said at least two secondary terminals is electrically coupled directly to a respective one of said at least two secondary windings without the secondary blocking capacitor.
In one embodiment, said at most one of said at least two primary terminals and said at most one of said at least two secondary terminals are of the same phase.
In one embodiment, the said at most one of said at least two primary terminals and said at most one of said at least two secondary terminals are of different phases.
In one embodiment, said at least two secondary windings are magnetically coupled to said at least two primary windings through a single magnetic core or at least two independent magnetic cores.
As shown in
An isolated DC/DC converter may utilize a transformer to provide galvanic isolation. To guarantee reliable operation of the DC/DC converter, it is extremely important to avoid saturation of the magnetic cores of the transformer by excessive flux density. To minimize the maximum flux density in the magnetic core, the DC component of the magnetizing current of the transformer should be zero. Note that magnetizing current is the current drawn by the primary side of a transformer that is being magnetized or energized at a specific voltage, but the secondary side is not loaded.
One method to eliminate the DC component of the magnetizing current is connecting a blocking capacitor in series with the transformer. In a steady state condition when charge balance of the capacitor is met, i.e., the charging current of the capacitor is equal to the discharging current during a switching cycle, the capacitor blocks the DC component of the magnetizing current. As a result, the transformer operates reliably without excessive magnetic flux.
where TS, iP, iS, and <iLM>TS represent the switching period of the converter, the current flowing through capacitor CP, the current flowing through capacitor CS, and the DC component of magnetizing current iLM which is equal to the average magnetizing current over switching period TS. In one embodiment, switching period TS may be 0.5 to 10 times to the inverse of a resonant frequency v of the serially connected inductor LM and capacitor CP (where v=½π√{square root over (LMCP)}). For example, switching period TS may be about 1 over several hundreds of kHz.
This method can be used to prevent saturation of transformer 300, because it does not require any additional control. However, in high power as well as high voltage applications, a plurality of capacitors are connected in series and in parallel to meet required voltage and current stresses, because commercially available capacitors have limited voltage and current ratings.
Each phase of converter 500 includes two switches coupled to a primary side of transformer 510 and two switches coupled to a corresponding secondary side of transformer 510. Specifically, as shown in
External inductors LPA, LPB, and LPC are connected in series with a respective winding of three-phase transformer 510 via a respective one of capacitors 520 to control the slope of the current through transformer 510. If the leakage inductance of each winding of the transformer is sufficiently large to control the slope of the current, external inductors LPA, LPB, and LPC become optional and can be removed.
Converter 500 in
As shown in
By applying Kirchhoff s current law to a neutral point 1021 of the Y-connected windings as shown in
iPA+iPB+iPC=0, (2)
where iPA, iPB, and iPC respectively represent the currents in terminals PA, PB, and PC. One can take an average of currents iPA, iPB, and iPC in Equation (2) over a switching period TS, which gives:
<iPA>+<iPB>+<iPC>=0, or (3)
<iPA>=−<iPB>−<iPC>, (4)
where <iPA>, <iPB>, and <iPC> respectively represent the average values of currents iPA, iPB, and iPC over switching period Ts. Due to charge balances of capacitors CPA and CPB, the average values of currents iPA and iPB are both zero, i.e.:
<iPA>=0, and (5)
<iPB>=0. (6)
By substituting Equations (5) and (6) into Equation (4), the average value of current iPC becomes:
<iPC>=0. (7)
Therefore, the presence or absence of a blocking capacitor at terminal PC does not make a difference for transformer 1020, especially when charge balance of the capacitors is met. Although the present disclosure describes the removal of capacitor CPC in transformer 1010 having a Y-connected configuration, it is appreciated that any arbitrary one of capacitors CPA, CPB, and CPC can be removed from transformer 1010 to achieve the same results. It is also appreciated that the removal of one of capacitors CPA, CPB, and CPC works in the same manner for transformers having a Δ-connected configuration.
For blocking capacitors having a capacitance that is synchronous to the switching frequency (namely, the resonant frequency is commensurate with the switching frequency), the removed blocking capacitors at the primary and secondary sides must be of different phases. For example, as shown in
For three-phase transformer 1100 as shown in
For the purposes of describing and defining the present disclosure, it is noted that terms of degree (e.g., “substantially,” “slightly,” “about,” “comparable,” etc.) may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. Such terms of degree may also be utilized herein to represent the degree by which a quantitative representation may vary from a stated reference (e.g., about 10% or less) without resulting in a change in the basic function of the subject matter at issue. Unless otherwise stated herein, any numerical value appearing in the present disclosure are deemed modified by a term of degree (e.g., “about”), thereby reflecting its intrinsic uncertainty.
Although various embodiments of the present disclosure have been described in detail herein, one of ordinary skill in the art would readily appreciate modifications and other embodiments without departing from the spirit and scope of the present disclosure as stated in the appended claims.
This application is a continuation of U.S. application Ser. No. 17/106,343, filed on Nov. 30, 2020, which claims the benefit of priority to U.S. Provisional Application No. 63/047,323, filed Jul. 2, 2020, the entire contents of both of which are incorporated herein by reference for all purposes.
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Child | 17812360 | US |