This application claims the benefit of European Patent Application No. 23183994.5 filed Jul. 6, 2023, the disclosure of which is incorporated herein by reference in its entirety.
This disclosure relates to flying capacitor multi-level (FCML) DC to DC voltage converters.
In various DC to DC voltage conversion applications, there are often large variations in either the input or output voltage. Various topologies of existing DC to DC voltage converters require a high degree of complexity of control of the circuit and/or have complex input EMI filtering requirements in order to accommodate these variations.
In various DC to DC voltage conversion applications, it may also be advantageous to reduce the voltage stresses across components. This may allow smaller components to be used in many applications. This may also lead to a prolonged lifetime of circuit components.
Other aims in many DC to DC voltage conversion applications include reducing losses, to reducing cooling requirements of the circuit. Reducing losses over certain components may result in a reduced cooling requirement for those components and/or it may result in prolonging the lifetime of those components.
In many DC to DC voltage applications, reducing the weight of the DC to DC voltage converter may also be of benefit.
When viewed from a first aspect, the present disclosure provides an n-level flying capacitor multi-level buck converter, for converting a DC input voltage into a DC output voltage provided at a load, comprising: an output filter comprising: an inductor arranged in series with an output capacitor and for arranging in series with the load; and the output capacitor arranged in series with the inductor and for arranging in parallel with the load; wherein the n-level flying capacitor multi-level buck converter comprises: a first pair of switching elements arranged in series with the DC input voltage; and a second pair of switching elements arranged in series with the DC input voltage; wherein each of the first and second pairs of switching elements comprises a first switching element and a second switching element; wherein the first switching element and the second switching element of the first pair of switching elements are arranged adjacent each other; wherein the first switching element of the second pair of switching elements is arranged adjacent to the first switching element of the first pair of switching elements; wherein the second switching element of the second pair of switching elements is arranged adjacent to the second switching element of the first pair of switching elements; and wherein the output filter is arranged in series with the first switching elements of the first and second pairs of switching elements, and in parallel with the second switching elements of the first and second pairs of switching elements; wherein the n-level flying capacitor multi-level buck converter further comprises a first flying capacitor in parallel with the first pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter is configured to: operate the first and second pairs of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operate the first and second pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
In some examples, the switching elements comprise a switch, a diode and a (e.g. parasitic) capacitance in parallel.
In various examples, any switching elements using actively controlled power semiconductor technology, such as metal-oxide-semiconductor field-effect transistors (MOSFETs), may be used. In various examples, instead of MOSFETs any of insulated-gate bipolar transistors (IGBTs), high-electron-mobility transistors (HEMTs) or bidirectional switches are used as alternatives, or in combination with MOSFETs.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a third pair of switching elements: wherein the third pair of switching elements is arranged in series with the DC input voltage; wherein the third pair of switching elements comprises a first switching element and a second switching element; wherein the first switching element of the third pair of switching elements is arranged adjacent to the first switching element of the second pair of switching elements; wherein the second switching element of the third pair of switching elements is arranged adjacent to the second switching element of the second pair of switching elements; wherein the output filter is arranged in series with the first switching element of the third pair of switching elements, and in parallel with the second switching element of the third pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter further comprises a second flying capacitor in parallel with the second pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter is configured to: operate the third pair of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operate the third pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
In some examples, the first switching element of each pair of switching elements is arranged to be switched off before the second switching element of each pair of switching elements is switched on; and the second switching element of each pair of switching elements is arranged to be switched off before the first switching element of each pair of switching elements is switched on.
In some examples, the n-level flying capacitor multi-level buck converter is arranged such that the current through the inductor is zero when the second switching element of each pair of switching elements is switched off.
In some examples, the n-level flying capacitor multi-level buck converter is arranged such that the current through the inductor is less than zero when the second switching element of each pair of switching elements is switched off.
In some examples, the n-level flying capacitor multi-level buck converter is arranged such that the current through the inductor is a predetermined value when the second switching element of each pair of switching elements is switched off.
In some examples, each pair of switching elements are arranged to operate out of phase with each other. Out of phase may be defined as operating asynchronously, i.e. not switching simultaneously.
In some examples, the pairs of switching elements are arranged to be triggered by a series of phase shifted pulses: wherein a phase shift of the phase shifted pulses corresponds to a number of active levels of the n-level flying capacitor multi-level buck converter; and wherein a pulse width of the phase shifted pulses corresponds to a duty cycle of the n-level flying capacitor multi-level buck converter.
In some examples, the n-level flying capacitor multi-level buck converter is configured to operate the pairs of switching elements to change a or the number of active levels of the n-level flying capacitor multi-level buck converter.
In some examples, the n-level flying capacitor multi-level buck converter is configured to reduce the number of active levels by switching on both the first switching element and the second switching element of the pair of switching elements arranged proximate to the DC input voltage.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a third pair of switching elements: wherein the third pair of switching elements are arranged in series with the DC input voltage; wherein the third pair of switching elements comprises a first switching element and a second switching element; wherein the first switching element of the third pair of switching elements is arranged adjacent to the first switching element of the second pair of switching elements; wherein the second switching element of the third pair of switching elements is arranged adjacent to the second switching element of the second pair of switching elements; wherein the output filter is arranged in series with the first switching element of the third pair of switching elements, and in parallel with the second switching element of the third pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter further comprises a flying capacitor in parallel with the second pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter is configured to further reduce the number of active levels by switching on both the first switching element and the second switching element of the pair of switching elements adjacent to the pair of switching elements which are arranged proximate to the DC input voltage.
In some examples, the n-level flying capacitor multi-level buck converter is configured to change the number of active levels depending on at least one of the input voltage, the output voltage or the ratio between the input voltage and the output voltage.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a controller arranged to generate a or the series of phase shifted pulses to trigger the pairs of switching elements of the n-level flying capacitor multi-level buck converter: wherein a or the phase shift of the phase shifted pulses corresponds to a or the number of active levels of the n-level flying capacitor multi-level buck converter; and wherein a or the pulse width of the phase shifted pulses corresponds to a or the duty cycle of the n-level flying capacitor multi-level buck converter.
In some examples, the controller further comprises a current feedback loop which adjusts a switching frequency of the switching elements based on a current through the inductor.
In some examples, the controller further comprises a voltage feedback loop which adjusts the duty cycle based on the at least one of the input voltage, the output voltage or the ratio between the input voltage and the output voltage.
When viewed from a second aspect, the present disclosure provides a method of operating an n-level flying capacitor multi-level buck converter, for converting a DC input voltage into a DC output voltage provided at a load, wherein the n-level flying capacitor multi-level buck converter comprises: an output filter comprising: an inductor arranged in series with an output capacitor and for arranging in series with the load; and the output capacitor arranged in series with the inductor and for arranging in parallel with the load; wherein the n-level flying capacitor multi-level buck converter comprises: a first pair of switching elements arranged in series with the DC input voltage; and a second pair of switching elements arranged in series with the DC input voltage; wherein each of the first and second pairs of switching elements comprises a first switching element and a second switching element; wherein the first switching element and the second switching element of the first pair of switching elements are arranged adjacent; wherein the first switching element of the second pair of switching elements is arranged adjacent to the first switching element of the first pair of switching elements; wherein the second switching element of the second pair of switching elements is arranged adjacent to the second switching element of the first pair of switching elements; and wherein the output filter is arranged in series with the first switching elements of the first and second pairs of switching elements, and in parallel with the second switching elements of the first and second pairs of switching elements; wherein the n-level flying capacitor multi-level buck converter further comprises a flying capacitor in parallel with the first pair of switching elements; wherein the method comprises: operating the first and second pairs of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operating the first and second pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a third pair of switching elements: wherein the third pair of switching elements is arranged in series with the DC input voltage; wherein the third pair of switching elements comprises a first switching element and a second switching element; wherein the first switching element of the third pair of switching elements is arranged adjacent to the first switching element of the second pair of switching elements; wherein the second switching element of the third pair of switching elements is arranged adjacent to the second switching element of the second pair of switching elements; wherein the output filter is arranged in series with the first switching element of the third pair of switching elements, and in parallel with the second switching element of the third pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter further comprises a second flying capacitor in parallel with the second pair of switching elements; and the method further comprises: operating the third pair of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operating the third pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
n some examples, the method further comprises operating the first and second pairs of switching elements such that the first switching element of each pair of switching elements is switched off before the second switching element of each pair of switching elements is switched on; and the second switching element of each pair of switching elements is switched off before the first switching element of each pair of switching elements is switched on.
In some examples, the method further comprises operating each pair of switching elements such that the current through the inductor is zero when the second switching element of each pair of switching elements is switched off.
In some examples, the method further comprises operating each pair of switching elements such that the current through the inductor is less than zero when the second switching element of each pair of switching elements is switched off.
In some examples, the method further comprises operating each pair of switching elements such that the current through the inductor is a predetermined value when the second switching element of each pair of switching elements is switched off.
In some examples, the method further comprises operating each pair of switching elements out of phase with each other.
In some examples, the method further comprises triggering the pairs of switching elements with a series of phase shifted pulses: wherein a phase shift of the phase shifted pulses corresponds to a number of active levels of the n-level flying capacitor multi-level buck converter; and wherein a pulse width of the phase shifted pulses corresponds to a duty cycle of the n-level flying capacitor multi-level buck converter.
In some examples, the method further comprises operating the pairs of switching elements to change a or the number of active levels of the n-level flying capacitor multi-level buck converter.
In some examples, the method further comprises reducing the number of active levels by switching on both the first switching element and the second switching element of the pair of switching elements arranged proximate to the DC input voltage.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a third pair of switching elements: wherein the third pair of switching elements is arranged in series with the DC input voltage; wherein the third pair of switching elements comprises a first switching element and a second switching element; wherein the first switching element of the third pair of switching elements is arranged adjacent to the first switching element of the second pair of switching elements; wherein the second switching element of the third pair of switching elements is arranged adjacent to the second switching element of the second pair of switching elements; wherein the output filter is arranged in series with the first switching element of the third pair of switching elements, and in parallel with the second switching element of the third pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter further comprises a second flying capacitor in parallel with the second pair of switching elements; and the method further comprises further reducing the number of active levels by switching on both the first switching element and the second switching element of the pair of switching elements adjacent to the pair of switching elements which are arranged proximate to the DC input voltage.
In some examples, the method further comprises changing the number of active levels depending on at least one of the input voltage, the output voltage or the ratio between the input voltage and the output voltage.
In some examples, the n-level flying capacitor multi-level buck converter further comprises a controller; and the method further comprises generating a or the series of phase shifted pulses to trigger the pairs of switching elements of the n-level flying capacitor multi-level buck converter: wherein a or the phase shift of the phase shifted pulses corresponds to a or the number of active levels of the n-level flying capacitor multi-level buck converter; and wherein a or the pulse width of the phase shifted pulses corresponds to a or the duty cycle of the n-level flying capacitor multi-level buck converter.
In some examples, the controller further comprises a current feedback loop; and the method further comprises adjusting a switching frequency of the switching elements based on a current through the inductor.
In some examples, the controller further comprises a voltage feedback loop; and the method further comprises adjusting the duty cycle based on the at least one of the input voltage, the output voltage or the ratio between the input voltage and the output voltage.
When viewed from a third aspect, the present disclosure provides an n-level flying capacitor multi-level buck converter, for converting a DC input voltage into a DC output voltage provided at a load, comprising: an output filter comprising: an inductor arranged in series with an output capacitor and for arranging in series with the load; and the output capacitor arranged in series with the inductor and for arranging in parallel with the load; wherein the n-level flying capacitor multi-level buck converter comprises: a first pair of switching elements arranged in series with the DC input voltage; and a second pair of switching elements arranged in series with the DC input voltage; wherein each of the first and second pairs of switching elements comprises a first switching element and a second switching element; wherein the first switching element and the second switching element of the first pair of switching elements are arranged adjacent each other; wherein the first switching element of the second pair of switching elements is arranged adjacent to the first switching element of the first pair of switching elements; wherein the second switching element of the second pair of switching elements is arranged adjacent to the second switching element of the first pair of switching elements; and wherein the output filter is arranged in series with the first switching elements of the first and second pairs of switching elements, and in parallel with the second switching elements of the first and second pairs of switching elements; wherein the n-level flying capacitor multi-level buck converter further comprises a first flying capacitor in parallel with the first pair of switching elements; and wherein the n-level flying capacitor multi-level buck converter is configured to operate the pairs of switching elements to change a number of active levels of the n-level flying capacitor multi-level buck converter.
In some examples, the n-level flying capacitor multi-level buck converter is further configured to: operate the first and second pairs of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operate the first and second pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
It will be appreciated that the optional features of the first aspect of the present invention relate equally to this aspect of the disclosure.
When viewed from a fourth aspect, the present disclosure provides a method of operating an n-level flying capacitor multi-level buck converter, for converting a DC input voltage into a DC output voltage provided at a load, wherein the n-level flying capacitor multi-level buck converter comprises: an output filter comprising: an inductor arranged in series with an output capacitor and for arranging in series with the load; and the output capacitor arranged in series with the inductor and for arranging in parallel with the load; wherein the n-level flying capacitor multi-level buck converter comprises: a first pair of switching elements arranged in series with the DC input voltage; and a second pair of switching elements arranged in series with the DC input voltage; wherein each of the first and second pairs of switching elements comprises a first switching element and a second switching element; wherein the first switching element and the second switching element of the first pair of switching elements are arranged adjacent; wherein the first switching element of the second pair of switching elements is arranged adjacent to the first switching element of the first pair of switching elements; wherein the second switching element of the second pair of switching elements is arranged adjacent to the second switching element of the first pair of switching elements; and wherein the output filter is arranged in series with the first switching elements of the first and second pairs of switching elements, and in parallel with the second switching elements of the first and second pairs of switching elements; wherein the n-level flying capacitor multi-level buck converter further comprises a flying capacitor in parallel with the first pair of switching elements; wherein the method comprises operating the pairs of switching elements to change a number of active levels of the n-level flying capacitor multi-level buck converter.
In some examples, the method further comprises: operating the first and second pairs of switching elements in a sequence to selectively apply a portion of the input voltage across the output filter; and operating the first and second pairs of switching elements such that each switching element is switched on when a voltage across the switching element is zero.
It will be appreciated that the optional features of the second aspect of the present invention relate equally to this aspect of the disclosure.
One or more non-limiting examples will now be described, by way of example only, and with reference to the accompanying figures in which:
Switching elements Q1107 and
There are two modes of operation of the three-level FCML buck converter 100 depending on the duty cycle. In the first mode of operation, the duty cycle is greater than half, i.e. Q1107 and Q2108 are each turned on for more than half of the cycle time, and the square wave voltage Vx 102 varies between Vin/2 and Vin 101. In the second mode of operation, the duty cycle is less than half, i.e. Q1107 and Q2108 are both turned on for less than half of the cycle time, and the square wave voltage Vx 102 varies between zero and Vin 101.
The first mode of operation of the three-level FCML buck converter 100 will be described with reference to various states of the circuit 100. It should be understood that when Q1107 is on
In the first state Q1107 is on and Q2108 is on, and therefore Vx 102 is equal to Vin 101. In the second state Q2108 turns off; hence Q1107 is on and Q2108 is off, and therefore Vx 102 is equal to the voltage Vc across the flying capacitor C1106. In the third state Q2108 turns back on; hence the third state is equivalent to the first state and Vx 102 is equal to Vin 101. In the fourth state Q1107 turns off; hence Q1107 is off and Q2108 is on, and therefore Vx 102 is equal to Vin 101 minus the voltage Vc across the flying capacitor C1106. In the final state, Q1107 turns back on, and the circuit state is equivalent to the first state hence Vx 102 is equal to Vin 101. Typically, the voltage Vc across the flying capacitor C1106 is equal to Vin/2, and therefore the square wave voltage Vx 102 alternates between Vin 101 and Vin/2.
The second mode of operation of the three-level FCML buck converter 100 will be described with reference to various states of the circuit 100.
In the first state Q1107 is off and Q2108 is off, and therefore Vx 102 is equal to zero. In the second state Q2108 turns on; hence Q1107 is off and Q2108 is on, and therefore Vx 102 is equal to Vin 101 minus the voltage Vc across the flying capacitor C1106. In the third state Q2108 turns back off; hence the third state is equivalent to the first state and Vx 102 is equal to zero. In the fourth state Q1107 turns on; hence Q1107 is on and Q2108 is off, and therefore Vx 102 is equal to the voltage Vc across the flying capacitor C1106. In the final state, Q1107 turns back off, and the circuit state is equivalent to the first state hence Vx 102 is equal to zero. Typically, the voltage Vc across the flying capacitor C1106 is equal to Vin/2, and therefore the square wave voltage Vx 102 alternates between zero and Vin/2.
The output filter (comprising the inductor L 104 and the output capacitor Cout 105) filters out AC components of the square wave voltage Vx 102. Therefore, a DC output voltage Vout is applied to the load Rload 103. This DC output voltage Vout is the stepped-down input voltage Vin 101. The ratio between Vin 101 and the voltage Vout applied to the load Rload 103 is dependent on the duty cycle.
The three-level FCML buck converter 100 is known as a three-level converter as it is able to operate between three voltage levels: zero, Vin/2 and Vin 101.
When
A mode of operation of the switching elements Q1107 and
As can be seen in
This mode of operation is known as quasi-square wave/zero voltage switching (QSW/ZVS). The value of izvs 210 is critical in ZVS operation of each of the pairs switching elements Q1107 and
Referring to
If the desired output voltage is V3303, the voltage Vds1209 across the drain source capacitance Cds of Q1107 reaches zero during the resonance, therefore QSW/ZVS can be achieved.
If the desired output voltage is V2302, this is the limit case to achieve QSW/ZVS for izvs equal to zero.
However, for a desired output voltage V1301, the vector length Ar1 is not large enough to ensure ZVS operation. Therefore, Q1107 cannot turn on ZVS because the voltage Vds1209 across the drain source capacitance Cds of Q1107 has not fully discharged when Q1107 must turn on.
The minimum input-to-output voltage relation required to achieve ZVS in a traditional two-level buck converter using izvs equal to zero can be defined as Vin>2Vout.
The input-to-output voltage relation required to achieve QSW/ZVS in a n-level FCML buck converter using izvs 210 equal to zero can be defined as Vin≥2Vout (n−1). Hence for the three-level FCML buck converter 100 of
However, as noted above, izvs 210 may be set to values smaller than zero to include output voltages larger than V2302 in the ZVS operation. This concept of having a negative izvs 210 is known as triangular condition mode (TCM) operation.
Operation of multi-level FCML buck converters using QSW/ZVS and QSW/TCM/ZVS modes of operation is a novel approach to operation of multi-level FCML buck converters. These operation modes may result in all of the benefits associated with soft switching operation of the switching elements, such as lower switching losses, lower cooling requirements and/or prolonged lifetime of the switching elements.
Typically, the voltage Vc1 across the flying capacitor C1406 is Vin/3, and the voltage Vc2 across the flying capacitor C2410 is 2Vin/3. Hence, any of four voltage levels: zero, Vin/3, 2Vin/3 or Vin 401 may be applied to Vx 402. Therefore, this circuit 400 is a four-level converter.
The general QSW/ZVS voltage condition for the n-level FCML buck converter 500, for izvs equal to zero, can be defined in terms of duty cycle D and the number of levels n as:
Hence, for higher level FCML buck converters, the duty cycle for which QSW/ZVS can be achieved, without operating TCM, reduces. The ratio of output voltage Vout to input voltage Vin depends on the duty cycle. Therefore, higher level FCML buck converters cannot achieve the same ratio of Vout to Vin as lower level FCML buck converters unless they operate TCM, i.e. a lower maximum value of Vout can be achieved for the same Vin.
A traditional two-level QSW/ZVS buck converter switching period Tsw2L can be defined as:
The n-level QSW/ZVS FCML buck converter 500 switching period TswnL can be defined as:
Hence, the switching period TswnL varies with both the number of levels of the n-level FCML buck converter 500 and the ratio between output voltage Vout to input voltage Vin. Therefore, if the ratio of Vout to Vin varies for a given number of levels of the FCML converter, so does the switching period. Note that Lbuck in this equation is the inductance of inductor L 504. Von is the voltage during the magnetization of the inductor (i.e. first switching element is on), Voff is the voltage over the inductor during the demagnetization (i.e. first switching element is off).
As can be seen in
It can also be seen in
Based on the above equation, and analysis of the n-level FCML buck converter 500, for a given desired output voltage Vout it is possible to operate the converter with a different active number of levels depending on the input voltage. This enables variation of the switching frequency to be reduced, while also ensuring QSW/ZVS operation may be achieved over the full range of input voltages without operating TCM, or operating TCM with only a relatively small negative value of izvs to avoid the conduction losses associated with larger negative values of izvs. Reducing the variation of the switching frequency can be particularly beneficial, as variable switching frequency may penalize the overall design, and particularly the EMI filter at the input to the converter (not shown).
The level switcher mode of operation may be defined as switching the number of active levels according to the ratio between the input voltage and desired output voltage of the converter. In some examples, the input voltage and the output voltage may both vary. In some examples, where the desired output voltage is constant and the input voltage varies, the level switcher mode of operation may switch the number of active levels according to the input voltage. In further examples, where only the desired output voltage varies while the input voltage is constant, the level switcher mode of operation may switch the number of active levels according to the output voltage.
The controller 1000 of
Based on the inputs received from the current feedback loop 1002 and the voltage feedback loop 1003, the pulse generator 1005 generates a series of phase shifted pulses. The pulse generator 1005 may also adjust control of the n-level FCML buck converter 900 to vary the number of active levels depending on either the input voltage Vin 901, the output voltage Vout 915 or both the input voltage Vin 901 and the output voltage Vout 915. The choice of basis for varying the number of active levels of the n-level FCML buck converter 900 may be based on whether variation is expected of the input voltage Vin 901, the output voltage Vout 915 or both the input voltage Vin 901 and the output voltage Vout 915.
The phase shift of the pulses generated by the pulse generator 1005 depends on the number of active levels of the n-level FCML buck converter 900. The switching frequency depends on the QSW/ZVS operation of the n-level FCML buck converter 900, and the pulse width depends on the duty cycle. The phase shifted pulses are received as inputs to the gate drivers 1006 of the switching elements of the n-level FCML buck converter 900 to trigger each of the switching elements of the n-level FCML buck converter 900.
The method comprises a first step 1101 of operating the pairs of switching elements, i.e. the first pair of switching elements Q1 and
The method 1100 further comprises a step 1102 of operating the pairs of switching elements such that each switching element turns on when the voltage across the switching element is zero, i.e. each switching element turns on ZVS.
This may be achieved by turning off a first switching element, e.g. Q1 to Qn−1, before turning on a second switching element, e.g.
When turning on the second switching element from a pair of switching elements, turning off of the first switching element may occur when the current through the inductor 504 is a pre-determined value of izvs. This pre-determined value of izvs may be zero or less than zero. This may ensure that the second switching element can turn on ZVS. A corresponding process may be used to turn on the first switching element from a pair of switching elements ZVS, by turning off the second switching element when the current through the inductor 504 is a pre-determined value of izvs.
The pairs of switching elements may operate in phase (or synchronously), i.e. the first switching element from each pair of switching element may all turn on and off simultaneously; and the second switching element from each pair of switching element may all turn on and off simultaneously. This would result in the output filter voltage 502 alternating between zero and Vin 501.
However, the pairs of switching elements may also operate out of phase (or asynchronously) in order to vary the output filter voltage 502 between any one of n voltage levels.
The method 1100 may further comprise generating a series of pulses 1103 in order to trigger the switching elements of the n-level FCML buck converter 500. The phase shift of the pulses may correspond with the number of active levels of the n-level FCML buck converter 500. In some examples, the pulses may be equally spaced apart within one cycle of operation of the n-level FCML buck converter 500. The pulse width may correspond with the duty cycle of the n-level FCML buck converter 500.
The method may further comprise varying the switching frequency 1104 of the n-level FCML buck converter 500 depending on current through the inductor 504. Varying the switching frequency may comprise varying the frequency of the series of phase shifted pulses.
The method may further comprise varying the duty cycle 1105 of the FCML buck converter depending on at least one of the input voltage Vin 501, the output voltage Vout or the ratio of the input voltage Vin 501 to the output voltage Vout. Varying the duty cycle may comprise varying the pulse width of the series of phase shifted pulses.
The method 1200 comprises a first step 1201 of operating the pairs of switching elements, i.e. the first pair of switching elements Q1 and
The method 1200 further comprises a second step 1202 of operating the pairs of switching elements to change the number of active levels of the n-level flying capacitor multi-level buck converter. The number of active levels may be reduced by turning on both of the switching elements of the final pair of switching elements Qn−1 and
The method 1200 may further comprise varying the number of active levels 1203 based on at least one of the input voltage Vin 501, the output voltage Vout 515, or the ratio between the input voltage Vin 501 and the output voltage Vout 515.
By operating an n-level FCML buck converter in a level switcher mode of operation, a reduction in variation of the switching period may be achieved. Reducing variation of the switching period may be particularly important in applications where the input voltage is likely to vary significantly. Such applications include aircrafts where DC power distribution is used. Here, the high voltages may be used in the aircraft's propulsion systems, while the lower voltages may be used elsewhere in the aircraft. In these applications, the high input voltage may have a wide variation, such as a variation between 400v to 750V. In some applications, the high voltage DC bus used in aircraft applications may even reach in excess of 3 kV. Therefore, the reduction on switching frequency range may lead to better EMI management and optimized EMI filter size.
Other important considerations in aerospace applications include volume and weight reduction. This is typically achieved in power converters by increasing frequency operation, which leads to size reduction of the passive elements (i.e., capacitors, inductors, etc.) which are key contributors to the overall volume and weight in power converters. However, it comes at the cost of higher switching losses and increased thermal dissipation. Consequently, both the semiconductor's temperature and the cooling system's size will increase, which are also limiting factors to be added to the passive elements volume and weight reduction. Hence, the importance of ZVS switching to reduce the switching losses, primarily as heat, is apparent in aerospace applications. This may enable the use of smaller and/or lighter cooling systems. Furthermore, ZVS switching operation may enable the converter to be smaller and/or lighter overall, e.g. by reducing the size of the cooling system or by enabling more freedom in design choices, such as selection of switches.
By removing part of the semiconductor's switching losses, the technique enables the power converter's switching frequency to increase, and the overall weight and volume of the system are reduced. Differently from other options to achieve ZVS, which rely on resonant converters or auxiliary circuits, the QSW can be applied to traditional DC-DC converters without the requirement of any extra circuits or complex control techniques. The simple design and implementation of the n-level QSW FCML buck converter 500 is able to be deployed with both analogue and digital control. Moreover, operating QSW necessarily requires larger current ripple at the power inductor which, apart from the switching frequency variable, can also lead to further reductions in the magnetics weight and volume.
Hence, the high voltage advantages of a multi-level converter as the FCML are combined to the high-frequency, low-losses, QSW and TCM operating modes to enable soft-switching of the switching elements. Therefore, the n-level FCML buck converter 500 may result in high-voltage, high-frequency, low-losses and reduced size converter, which is particularly interesting for electrified aircrafts with high voltage DC distribution.
If compared to a traditional two-level buck converter, the n-level FCML buck converter 500 at the same switching frequency has much smaller passive components and voltage stress over the semiconductors, e.g. the voltage across each switching element is significantly lower. This already sets a clear advantage in power density and specific power over a two-level buck converter despite the increased number of active components. For example, this may result in a significant reduction on breakdown voltage for devices, enabling the use of automotive graded GaN or Si devices for HV applications. By applying a QSW ZVS technique to the converter, its switching frequency can be pushed higher resulting in even greater achievements in power density and specific power. Such an outcome can be very beneficial in an aerospace market moving towards more electrified aircrafts, where more and more DC/DC interfaces to energy storage systems are required.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
Number | Date | Country | Kind |
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23183994.5 | Jul 2023 | EP | regional |