阅读说明：本技术 用于操作电子功率转换器的方法和电子功率转换器 (Method for operating an electronic power converter and electronic power converter ) 是由 M·莱布尔 S·朗 E·纳泽拉吉 L·瑞格乐 于 2020-03-18 设计创作，主要内容包括：一种用于操作电子功率转换器(1)的方法,该转换器(1)包括初级DC链路电压V<Sub>p</Sub>与变压器(3)的初级侧之间的初级桥(23),以及次级DC链路电压V<Sub>s</Sub>与变压器(3)的次级侧之间的次级桥(43)。为了控制从转换器(1)的初级侧到次级侧的电功率流,执行以下步骤：在给定转换器(1)的操作点的情况下,选择用于转换器(1)的操作的导通模式、以及相应的占空比d和相移g,控制初级桥(23)向变压器(3)提供占空比为d的电压脉冲,以及通过仅有源地切换两个开关单元来控制次级桥(43),以向变压器(3)提供具有相移g的电压脉冲。(A method for operating an electronic power converter (1), the converter (1) comprising a primary DC-link voltage V p A primary bridge (23) with the primary side of the transformer (3), and a secondary DC link voltage V s And a secondary bridge (43) between the secondary side of the transformer (3). In order to control the flow of electrical power from the primary side to the secondary side of the converter (1), the following steps are performed: selecting a conduction mode for operation of the converter (1), and a corresponding duty cycle d and phase shift g, controlling the primary bridge (23) to provide voltage pulses of duty cycle d to the transformer (3), and controlling the secondary bridge (4) by actively switching only two switching units, given an operating point of the converter (1)3) To supply voltage pulses with a phase shift g to the transformer (3).)

1. A method for operating an electronic power converter (1), the converter (1) comprising

A primary bridge circuit (23) arranged to couple at least a primary DC-link voltage V from a primary side of the converter (1)_pOr the primary DC link voltage-V to be inverted_pIs provided to the primary side of the transformer (3), an

A secondary bridge circuit (43) arranged to couple at least a secondary DC link voltage V from a secondary side of the converter (1)_sOr the inverted secondary DC link voltage-V_sProvided to the secondary side of the transformer (3), the secondary bridge circuit (43) comprising two half-bridges, each half-bridge comprising an upper switching cell and a lower switching cell,

characterized in that the method comprises the following steps in order to control the flow of electrical power from the primary side to the secondary side of the converter (1):

determining an operating point of the converter (1), the operating point being the primary DC link voltage V_pStation, stationThe secondary DC link voltage V_sAnd an electric power P to be transmitted from the primary side to the secondary side,

determining from the operating point a selected conduction mode for operation of the converter (1), the selected conduction mode being one of at least three conduction modes,

for the selected conduction mode, the duty cycle value d and the phase shift value g are determined,

-for the selected conduction mode, controlling the primary bridge circuit (23) to provide alternating positive and negative voltage pulses to the primary side of the transformer (3), the voltage pulses having a duty cycle with respect to a switching period according to the duty cycle value d,

-for the selected conduction mode, controlling the secondary bridge circuit (43) by actively switching only two switching units of the secondary bridge circuit (43) to provide alternating positive and negative voltage pulses to the secondary side of the transformer (3), the voltage pulses having a phase shift with respect to the voltage pulses provided to the primary side of the transformer (3) according to the phase shift value g.

2. The method of claim 1, wherein,

-the step of controlling the secondary bridge circuit (43) comprises: for a first and a second of the two actively switched switching units of the secondary bridge circuit (43), in each switching cycle after the phase shift, the first switching unit is switched on and the second switching unit is switched off, and then

After a duration of up to half the switching period, the first switching unit is switched off and the second switching unit is switched on.

3. The method of claim 2, wherein the duration is equal to half of the switching period.

4. The method of claim 1 or 2 or 3,

the step of controlling the secondary bridge circuit (43) comprises:

-only the lower switching unit (49b) of the secondary bridge circuit (43) is actively switched, while the upper switching units (49a,49c) are operated only as diodes,

or only actively switching the upper switch unit (49a) of the secondary bridge circuit (43), while the lower switch unit (49b) operates only as a diode.

5. A method according to claim 1 or 2 or 3, wherein

The step of controlling the secondary bridge circuit (43) comprises:

-actively switching only the upper and lower switching cells of one of the half-bridges (41; 42), while the upper and lower switching cells of the other of the half-bridges (42; 41) operate only as diodes.

6. The method of any one of the preceding claims,

-determining the start of a positive or negative voltage pulse applied to the secondary side of the transformer (3) by actively switching two switching units;

the positive end of a positive or negative voltage pulse applied to the secondary side of the transformer (3) is determined by one of the switching units, only one of the switching units operating as a diode being switched to the off-state due to the current flowing through the respective switching unit reversing its direction.

7. The method of any one of the preceding claims,

the at least three conduction modes include:

continuous Conduction Mode (CCM), in which

o if V_s'<V_pDepending on the operating point, the primary-side duty cycle according to the duty cycle value d is changed, and if V_s'>V_pThen the primary side duty cycle remains constant at 50%; whereinIs referenced to the secondary DC link voltage of the primary side,

a first discontinuous conduction mode (DCM1) in which

o, depending on the operating point, varying the primary side duty cycle according to the duty cycle value d,

a second discontinuous conduction mode (DCM2) in which

o the primary side duty cycle according to the duty cycle value d is kept constant at 50%.

8. The method of claim 7, wherein

Depending on the operating point, the boundaries between the conduction patterns are determined by the following rules:

if V_s'<V_pAnd the power P is less than

Said first discontinuous conduction mode (DCM1) applies;

if V_s'>V_pAnd the power P is less than

Said second discontinuous conduction mode (DCM2) applies;

otherwise the Continuous Conduction Mode (CCM) applies;

wherein V_pIs the primary DC link voltage, V_s' is referenced to the secondary DC link voltage of the primary side,wherein N is_pIs the number of turns of the primary winding, N_sIs the number of turns of the secondary winding, where f is the switching frequency, L_sIs with reference to the leakage inductance of the primary side and the absolute value of P is used.

9. The method according to claim 7 or 8, comprising the steps of:

for each conduction mode, parameters d and g are calculated to minimize an objective function, wherein the objective function is the transformer peak current, or wherein the objective function is the transformer RMS current.

10. The method of any one of the preceding claims,

in each switching mode, the parameters d and g depend on the power P transferred from the primary side to the secondary side, the primary DC-link voltage V_pAnd the secondary DC link voltage V_sOr with reference to the secondary DC-link voltage V of the primary side_s' to determine.

11. The method according to any of the preceding claims, wherein the converter (1) is a dual active bridge converter, i.e. the primary (2) and secondary (4) switching circuits are both full bridge inverters.

12. An electronic power converter (1), the converter (1) comprising a control unit (5), the control unit (5) comprising an analog and/or digital signal processing unit configured to perform the method according to any of the preceding claims.

13. An electronic power converter (1), the converter (1) comprising

A primary bridge circuit (23) arranged to provide at least a primary DC link voltage V from a primary side of the converter (1)_p(or DC input voltage), or primary DC link voltage-V to be inverted_pIs supplied to the primary side of the transformer (3), an

A secondary bridge circuit (43) arranged to provide at least a secondary DC link voltage V from a secondary side of the converter (1)_s(DC output voltage), or the secondary DC link voltage-V to be inverted_sIs provided to the secondary side of the transformer (3),

a secondary switching circuit (4) comprising:

active switching units (49b) of the secondary bridge circuit (43) are present only in the lower half of each half-bridge, each half-bridge connecting the respective bridge midpoint to the negative output terminal (14), while the upper switching unit (49c) connects the respective bridge midpoint to the positive output terminal (13) comprising only diodes,

or the active switching cells (49a) of the secondary bridge circuit (43) are present only in the upper half of each half-bridge, each half-bridge connecting the respective bridge midpoint to the positive output terminal (13), while the lower switching cells connect the respective bridge midpoint to the negative output terminal (14) comprising only diodes.

Technical Field

The present invention relates to the field of power electronics, and more particularly to power converters used in on-board chargers for electric vehicles. The invention relates to a method for operating an electronic power converter and an electronic power converter.

Background

The requirements of Electric Vehicle (EV) on-board chargers (OBCs) typically dictate bidirectional power transfer capability. The primary application of this technology is vehicle-to-vehicle charging (V2V), which allows the empty battery of one EV to be charged from the full battery of another EV. Other applications are vehicle-to-load (V2L), which means that the vehicle provides AC power to electrical devices connected to outlets within an EV or vehicle-to-grid (V2G), where the EV supplies power to the utility grid during peak demand.

OBCs are typically composed of a Power Factor Compensation (PFC) rectifier followed by an isolated DCDC converter. For the most advanced unidirectional OBCs, the well-known resonant converter LLC topology is widely used in DCDC converter stages. Since LLC is a unidirectional topology, it must be extended to CLLC for bidirectional power transfer. Since the secondary side operates in half-bridge mode, i.e. the low-side IGBT is always conducting in the discharge mode, the CLLC typically provides only 50% of the charging power in the discharge mode. Furthermore, CLLC inherits the disadvantages of LLC, namely variable switching frequency and necessary resonant capacitors.

An alternative product to CLLC is a Dual Active Bridge (DAB) converter (fig. 1), which provides full power transmission in both directions. Other advantages of DAB are that it does not require a resonant capacitor and operates at a constant switching frequency.

The DAB-converter comprises two full bridges, one on the primary side and one on the secondary side of the transformer, with defined integrated leakage and magnetizing inductances. There are three control variables: a primary duty cycle, a secondary duty cycle, and a phase shift between the primary side and the secondary side. Since all three control variables affect the output power, there are two degrees of freedom available to ensure Zero Voltage Switching (ZVS) is achieved at the semiconductor switches (typically MOSFETs) and conduction losses are minimized. However, ZVS can only be achieved if the switches are controlled in the correct way. This has proven to be feasible theoretically, but does not take into account real world component tolerances, measurement errors, parasitic capacitance and body diode reverse recovery, and operating conditions that may result in ZVS loss.

The following publications disclose the use of dual active bridge circuits

Krismer F. et al, Performance Optimization of a High Current Dual active bridge with a side Operating Voltage Range, POWER ELECTRICAL SPECIALIS TSC ONFERENCE,2006 IEEE June 18,2006.

·Florian Krismer:Modeling and optimization of bidirectional dualactive bridge DC-DC converter topologies,DISS.ETH NO.19177(2010)-Chapter 3.1.

·Nikolas Schibli:Symmetrical multilevel converters with two quadrantDC-DC feeding.

Polytechnique Fédérale de Lausanne,Dissertation N°2200(2000)–Chapter 4.

Krismer F. et al, A comparative evaluation of isolated bi-directional DC/DC converters with input and output voltages ranges, Conference Recordof Tth 2005IEEE Industry Applications Conference for energy IAS analysis, IEEE CAT., Bd.1,2.Oktober 2005(2005-10-02).

·US 2015/365005 Al

·CH 707 553 A2

However, all the circuits and control methods proposed therein have the above-mentioned problems.

Disclosure of Invention

It is therefore an object of the present invention to create a method for operating an electronic power converter and an electronic power converter of the initially mentioned kind which overcome the above-mentioned disadvantages. In particular, the aim may be to reduce switching losses in case the parameters affecting the operation of the circuit are not fully known or controllable. The object may be to provide an alternative method to reduce switching losses in converters, in particular dual active bridge converters.

These objects are achieved by a method for operating an electronic power converter and an electronic power converter according to the present invention.

The method is for operating an electronic power converter, the converter comprising:

a primary bridge circuit arranged to convert at least a primary DC link voltage V from the primary side of the converter_p(or DC input voltage), or primary DC link voltage-V to be inverted_pIs provided to the primary side of the transformer,

and a secondary bridge circuit arranged to convert at least a secondary DC link voltage V from the secondary side of the converter_s(DC output voltage), or the secondary DC link voltage-V to be inverted_sProvided to the secondary side of the transformer, a secondary bridge circuit comprising two half-bridges, each half-bridge comprising an upper switching cell and a lower switching cell,

the method comprises the steps of controlling the flow of electrical power from the primary side to the secondary side of the converter:

determining the operating point of the converter, which is the primary DC link voltage V_pSecondary DC link voltage V_sAnd the electrical power P to be transmitted from the primary side to the secondary side,

determining from the operating point a selected conduction mode for operation of the converter, the selected conduction mode being one of at least three conduction modes,

for the selected conduction mode, the duty cycle value d and the phase shift value g are determined,

for the selected conduction mode, the primary bridge circuit is controlled to supply alternating positive and negative voltage pulses to the primary side of the transformer, the voltage pulses having a duty cycle with respect to the switching period according to a duty cycle value d,

for the selected conduction mode, the secondary bridge circuit is controlled by actively switching only the two switching units of the secondary bridge circuit to provide alternating positive and negative voltage pulses to the secondary side of the transformer, which voltage pulses have a phase shift with respect to the voltage pulses provided to the primary side of the transformer according to the phase shift value g.

This allows to use only two variables (duty cycle value d and phase shift value g) to control the power flow through the converter and to reduce the switching losses in the secondary bridge circuit, since its remaining switching cells (usually two) are not actively switched. They are only passively switched.

Actively switching or actively controlling a switch or a switching unit means controlling an active switch by a switching signal or a gate signal to turn on or off the switch. The respective gate terminals of the switches are separated from the terminal through which the switched current flows. Conversely, when the voltage across the diode changes polarity, passive switching occurs, causing the diode to block or direct current through the diode. Actively switched switching cells comprise active switches and usually comprise parallel freewheeling diodes. In a particular mode of operation, only the passively switched switching unit may comprise only a diode. It may also comprise an active switch in parallel with the diode, but which is not operated in this particular mode of operation. Thus, a switching unit that operates only as a diode may be implemented by a diode alone, or by a diode with an active switch in parallel, wherein the active switch does not operate.

It will be appreciated that when only two switching cells of the secondary bridge circuit are actively switched and only the remaining switching cells are passively switched, this is done for the selected conduction mode, i.e. over a number of switching cycles. In other words, over the duration of a plurality of switching cycles, it is the case that only two switching cells of the secondary bridge circuit are actively switched, while the remaining two are passively switched. Such a plurality of switching cycles may comprise, for example, ten or fifty or one hundred or more switching cycles.

The switching period is the shortest time period after which the pattern or sequence of switching operations in the converter repeats itself.

The phase shift between positive voltage pulses is defined as the time between the rising edges of the pulses divided by the switching period. The time between falling edges may be different.

The phase shift between negative voltage pulses is defined as the time between the falling edges of the pulses divided by the switching period. The time between rising edges may be different.

In an embodiment of the present invention,

the step of controlling the secondary bridge circuit comprises: in each switching period after the phase shift, for a first switching unit and a second switching unit of the two actively switched switching units of the secondary bridge circuit, the first switching unit is switched on and the second switching unit is switched off, and then

After a duration of up to half the switching period, the first switching unit is switched off and the second switching unit is switched on.

In an embodiment, the duration is equal to half of the switching period.

In an embodiment, the step of controlling the secondary bridge circuit comprises:

only the lower switching unit of the secondary bridge circuit is actively switched, while the upper switching unit operates only as a diode,

or only actively switching the upper switching unit of the secondary bridge circuit, while the lower switching unit operates only as a diode.

Typically, the lower switching unit is arranged between the bridge midpoint of the secondary bridge circuit and the negative output terminal, and the upper switching unit is arranged between the bridge midpoint and the positive output terminal.

In an embodiment, the step of controlling the secondary bridge circuit comprises

The upper and lower switching cells of one of the half-bridges are actively switched, while the upper and lower switching cells of the other of the half-bridges are operated only as diodes.

Typically, a dead time is inserted between the switching of the upper and lower switching units.

In an embodiment of the present invention,

determining the start of a positive or negative voltage pulse applied to the secondary side of the transformer by actively switching the two switching units;

the positive side of the positive or negative voltage pulse applied to the secondary side of the transformer is determined by one of the switching units, only one of the switching units operating as a diode being switched to the off-state due to the current flowing through the respective switching unit reversing its direction.

In an embodiment, the at least three conduction modes include:

continuous Conduction Mode (CCM), in which

Omicron if V_s'<V_pDepending on the operating point, the primary-side duty cycle is changed according to the duty cycle value d, and if V_s'>V_pThen the primary side duty cycle remains constant at 50%; whereinIs referenced to the secondary DC link voltage on the primary side,

a first discontinuous conduction mode (DCM1) in which

Depending on the operating point, the primary-side duty cycle according to the duty cycle value d is changed,

a second discontinuous conduction mode (DCM2) in which

O primary side duty cycle according to duty cycle value d is kept constant at 50%.

In an embodiment, depending on the operating point, the boundary between the conduction modes is determined by the following rule:

if V_s'<V_pAnd the power P is less than

DCM1 applies;

if V_s'>V_pAnd the power P is less than

DCM2 applies;

otherwise, CCM is applicable;

wherein V_pIs the primary DC link voltage, V_s' is referenced to the secondary DC link voltage on the primary side,

wherein N is_pIs the number of turns of the primary winding, N_sIs the number of turns of the secondary winding, where f is the switching frequency, L_sIs the leakage inductance of the reference primary side and the absolute value of P is used.

The boundaries between conduction modes as described above may be replaced by other expressions using other mathematically or physically equivalent variables of the converter.

The power P is negative if power is to be transmitted from the secondary side. In this case, the definitions of the primary and secondary sides are interchanged, as are the number of turns of the transformer.

The operating point may be determined by measuring the two DC-link voltages and taking the power P as an input variable, the power P being generated, for example, by a monitoring unit. The operating point varies with time, but within the duration of one switching cycle it can be assumed to be stationary.

The absolute value of P is used because P can be positive or negative depending on the direction of power transfer.

In an embodiment, the method comprises the steps of:

for each conduction mode, the parameters d and g are calculated to minimize an objective function, in particular wherein the objective function is the transformer peak current, or wherein the objective function is the transformer RMS current.

The transformer peak current may be determined as the maximum of the absolute value of the transformer current during the switching period. The transformer RMS may be determined as the RMS value of the transformer current during the switching period.

In an embodiment, in each switching mode, the parameters d and g are dependent on the power P transferred from the primary side to the secondary side, the primary DC-link voltage V_pSecondary DC link voltage V_s(optionally referenced to the secondary DC link voltage V on the primary side_s') to be determined.

In an embodiment, the converter is a dual active bridge converter, i.e. both the primary and secondary switching circuits 4 are full bridge inverters.

In a full-bridge inverter, each half-bridge comprises two switching cells, each switching cell comprising an active switch and a freewheeling diode connected in parallel.

The electronic power converter comprises a control unit comprising an analog and/or digital signal processing unit configured to perform the methods described herein. The control unit typically further comprises means for measuring the primary DC-link voltage V_pAnd a secondary DC link voltage V_sAnd/or an input channel or input means for the voltage thus measured, and/or an input channel or input means for the desired power flow from the primary side to the secondary side, or vice versa.

In an embodiment, there is provided an electronic power converter comprising:

a primary bridge circuit arranged to provide at least a primary DC link voltage V from a primary side of the converter_p(or DC input voltage), or primary DC link voltage-V to be inverted_pIs supplied to the primary side of the transformer, an

A secondary bridge circuit arranged to provide at least a secondary DC link voltage V from the secondary side of the converter_s(DC output voltage), or the secondary DC link voltage-V to be inverted_sTo the secondary side of the transformer. The secondary switching circuit includes:

the active switching cells of the secondary bridge circuit are present only in the lower half of each half-bridge, each half-bridge connecting the respective bridge midpoint to the negative output terminal (14), while the upper switching cells connect the respective bridge midpoint to the positive output terminal comprising only diodes,

or the active switching cells of the secondary bridge circuit are present only in the upper half of each half-bridge, each half-bridge connecting the respective bridge midpoint to the positive output terminal, while the lower switching cells connect the respective bridge midpoint to the negative output terminal (14) comprising only diodes.

In summary, the above control method can achieve ZVS, minimize transformer peak current, and is robust to the effects of parasitic circuit elements. At high output power levels, the converter, in particular the DAB converter, operates in Continuous Conduction Mode (CCM).

At lower power output levels, it operates in Discontinuous Conduction Mode (DCM). One of two different DCMs is selected depending on the ratio of the input and output DC link voltages and the power level.

Other embodiments are apparent from other aspects of the invention. Features of the method claims may be combined with features of the apparatus claims and vice versa.

Drawings

The subject matter of the invention will be explained in more detail below with reference to exemplary embodiments shown in the drawings, which schematically show:

FIG. 1 is a Dual Active Bridge (DAB) converter;

FIG. 2 is an ideal waveform in Continuous Conduction Mode (CCM);

fig. 3 is a waveform in CCM with Vs' < Vp and a dead time Td, which is the dead time or delay time used in the primary side half bridge to prevent breakdown (i.e. short circuit of the primary DC link);

fig. 4 is a waveform with Vs' > Vp and dead time Td in CCM;

FIG. 5 is the conduction mode of DAB as a function of power level P/P0 and voltage ratio Vs'/Vp;

FIG. 6 is the switching interval, voltage and current of a CCM;

FIG. 7 is the switching interval, voltage and current of discontinuous conduction mode 1(DCM 1);

FIG. 8 is the switching interval, voltage and current of discontinuous conduction mode 2(DCM 2);

FIG. 9 is a waveform with Vs' < Vp and dead time Td in DCM 1;

fig. 10 is a waveform with Vs' > Vp and dead time Td in DCM 2;

FIG. 11 is an ideal waveform CCM for reverse power flow;

figure 12 is a one-way variant of a DAB converter; and

fig. 13 is a flow chart of a method for controlling a converter.

Detailed Description

The reference symbols used in the drawings and their meanings are listed in summary form in the list of reference symbols. In principle, identical parts in the figures have identical reference numerals.

Fig. 1 schematically shows a Dual Active Bridge (DAB) converter. It can be controlled from having a primary DC link voltage V_p(also written as V _ p or Vp) has a secondary DC link voltage V in the primary side direction_sThe secondary side of (V _ s, Vs) transmits electric power, or transmits electric power from the secondary side to the primary side.

On the primary side or input side, the converter 1 comprises a primary switching circuit 2 having a positive input terminal 11 and a negative input terminal 12, which may be connected to the DC-link of the PFC of the OBC. The primary switching circuit 2 comprises a primary bridge circuit 23 with two half bridges 21, 22 and a primary DC link capacitance 24. Each of the two primary terminals of the transformer primary winding is connected to a respective bridge midpoint 27, 28 of one of the half- bridges 21, 22. Thus, the primary bridge circuit 23 can transform the primary transformer voltage V_Tp(V _ Tp) is supplied to the primary terminal of the transformer 3. In particular, the voltage may be a variable duty cycle square wave.

The transformer 3 can be represented with Np turns in the primary winding and Ns turns in the secondary winding, a series inductance Ls in series and a magnetizing inductance Lm in parallel with one of the windings.

On the secondary side or output side, the converter 1 comprises a secondary switching circuit 4, which secondary switching circuit 4 has a positive output terminal 13 and a negative output terminal 14 connectable to a battery. The secondary switching circuit 4 comprises a secondary bridge circuit 43 with two half bridges 41, 42 and a secondary DC link capacitance 44. Each of the two terminals of the transformer secondary winding is connected to a respective bridge midpoint 47, 48 of one of the half- bridges 41, 42. Thus, the secondary bridge circuit 43 can transform the secondary transformer voltage V_Ts(V _ Ts) is supplied to the secondary terminal of the transformer 3. In particular, the voltage may be a variable duty cycle square wave.

In the primary bridge circuit 23, each half- bridge 21, 22 is arranged to connect the associated bridge midpoint 27, 28 to either the positive input terminal 11 or the negative input terminal 12. This is achieved by the switching units 29a, 29b, in particular by the upper switching unit 29a and the lower switching unit 29 b. The upper switch unit 29a is arranged between the respective bridge midpoint 27, 28 and the positive input terminal 11. The lower switching cells 29b are arranged between the respective bridge mid-points 27, 28 and the negative input terminal 12.

In the secondary bridge circuit 43, each half- bridge 41, 42 is arranged to connect the associated bridge midpoint 47, 48 to either the positive output terminal 13 or the negative output terminal 14. This is achieved by the switching units 49a,49 b, in particular by the upper switching unit 49a and the lower switching unit 49 b. The upper switching unit 49a is arranged between the respective bridge midpoint 47, 48 and the positive output terminal 13. The lower switching unit 49b is arranged between the respective bridge midpoint 47, 48 and the negative output terminal 14.

In an embodiment, the switching unit may be an active switching unit implemented by semiconductor switches S1, S2, S3, S4, S5, S6, S7, S8 (e.g., MOSFETs) in parallel with diodes. In an embodiment, one or more of the switching cells may be passive switching cells implemented by only the diode 49, and the other switching cells are active switching cells.

At high output power levels, DAB operates in Continuous Conduction Mode (CCM). For this mode, typical waveforms of the primary transformer voltage (V _ Tp), the secondary transformer voltage (V _ Ts), and the primary transformer current (I _ Lp), as well as the primary side gate signals S1-S4 and the secondary side gate signals S5-S8 are shown in fig. 2.

The control method uses only two control variables: as shown in fig. 2, the primary duty cycle d and the phase shift g specify a time relative to the switching period T _ s of 1/f. Since both control variables affect the amount of power transfer, the available degrees of freedom can be used to reduce the transformer peak current.

Continuous conduction mode

The continuous conduction mode uses a switching sequence based on fig. 2, but with a dead time T between switching operations of the primary side half bridge_dTo prevent breakdown.

An example waveform of CCM with dead time and gate signal generation is shown in fig. 3 for Vs '< Vp and in fig. 4 for Vs' > Vp.

In the waveform according to fig. 3, the converter experiences the following states in each switching cycle (only active switches S1-S8 are recorded as being on, i.e. conducting, i.e. in the conducting state; the other switches are in the off state):

a) s2, S4, S6 are on.

The primary current is negative, and circulates through S2 and S4,

voltage V of primary transformer_TpIs zero.

The secondary current is negative, and flows through the diodes of S6 and S7,

voltage V of secondary transformer_TsIs a reversed secondary DC link voltage V_s。

The primary and secondary currents begin to increase.

b) S2 is turned off, and after a delay time Td, S1 is turned on.

The primary current is negative, and flows through S1 and S4,

voltage V of primary transformer_TpIs the primary DC link voltage V_p。

V_TpThe duty cycle of the positive voltage pulse in (1) begins.

The primary and secondary currents continue to increase.

c) The primary and secondary currents change their signs from negative to positive. The diode of S7 is turned off and its current is taken over by S8.

The secondary current is positive, and circulates through S6 and S8,

voltage V of secondary transformer_TsIs zero.

d) After a phase shift g relative to the turn-off of S2, S6 turns off and S8 simultaneously turns on.

The secondary current, being positive, flows through S8 and S5,

voltage V of secondary transformer_TsIs the secondary DC link voltage V_s。

The primary and secondary currents continue to increase.

e) S4 is turned off, and after a delay time Td, S3 is turned on.

The primary current is positive, and cycles through S1 and S3,

voltage V of primary transformer_TpIs zero.

V_TpThe duty cycle of the positive voltage pulse in (1) ends.

The primary and secondary currents begin to decrease.

f) S1 is turned off, and after a delay time Td, S2 is turned on.

The primary current is positive, and flows through S2 and S3,

voltage V of primary transformer_TpIs an inverted primary DC link voltage V_p。

V_TpThe duty cycle of the negative voltage pulse in (1) is started.

The primary and secondary currents continue to decrease.

g) The primary and secondary currents change their signs from positive to negative. The diode of S5 is turned off and its current is taken over by S6.

The secondary current is negative, and circulates through S6 and S8,

voltage V of secondary transformer_TsIs zero.

h) After turning on half the switching period, S8 turns off, and S6 turns on simultaneously.

The secondary current, which is negative, flows through S6 and S7,

voltage V of secondary transformer_TsIs a reversed secondary DC link voltage V_s。

The primary and secondary currents continue to decrease.

State a) is reached again by switching off S3 and switching on S4 after a delay time Td).

When the switch is turned on and the switch is connected in parallel with a diode that has conducted current through the switching cell, a significant zero voltage switching occurs. Zero voltage switching also occurs at the beginning of state e), similar to phase shifted full bridge operation: when S4 is turned off, the current charges the parasitic capacitance of S4 and simultaneously discharges S3 until the body diode of S3 is activated. From then on, S3 may be safely turned on by the zero voltage switch. At the beginning of state a), this is also the case when subsequently S4 is switched on again.

The sequence of states of the converter within a switching cycle can be derived from the following fig. 4, 6-8 in the same way as the states described above.

In FIG. 4, Vs'>Vp, the waveform is similar to that of FIG. 3, except that the duty cycle d of the voltage pulses on the primary side is 50%, i.e. the primary transformer voltage V_TpEach positive and negative pulse of (a) has a length of half of the switching period. In other words, S2 and S3 are simultaneously turned off and on, and likewise, S1 and S4 are simultaneously turned off and on. This results in a primary transformer voltage V_TpFrom the primary DC link voltage V_pDirect jump to inverted primary DC link voltage V_pAnd then back again without a phase of zero.

In each case, the secondary transformer voltage V_TsIs determined by the secondary current changing its sign and the diode of S5 or S7 being turned off, respectively. The switched-off current is then forced to flow through the diodes of the respective opposite switching cells of the same half-bridge. This results in a secondary current circulation, the secondary transformer voltage V_TsBecomes zero. This concludes the secondary transformer voltage V_TsThe duty cycle of (c). The same or similar sequence of events occurs in other conduction modes when the secondary current changes its sign.

The switches of the secondary bridge circuit 43 in use (in this example, the lower switches S6 and S8) may then be switched (from on to off and off to on, respectively) at zero voltage to start the duty cycle of the next voltage pulse. Thus, the switches have a constant duty cycle (half a switching cycle) of 50%, while the secondary voltage has a shorter duty cycle, terminated by passive switching of the respective diodes, as described in the preceding paragraph.

Boundary between continuous and discontinuous conduction modes

At lower output power levels, DAB operates in Discontinuous Conduction Mode (DCM). Depending on the ratio of the DC link voltages and the power level, there are two different DCMs (DCM1 and DCM 2). The conduction mode is shown in fig. 5 as a function of the transmission power P (the vertical axis is normalized with respect to the base power)

The maximum power that can be transmitted in CCM is

If V_s'<V_pAnd the power P is less thanDCM1 applies. If V_s'>V_pAnd the power P is less thanDCM2 applies.

Determining control variables d and g

In each switching mode, the same method can be used to derive the primary DC link voltage V_pReference to the secondary DC link voltage of the primary side

And the power P to be transmitted determines the parameters d and g.

(Note: it is well known that given a circuit with a transformer, an equivalent circuit can be used based on the transformer ratio

Simulating its behavior with circuit elements and with reference to the electrical quantity on one side of the transformer on the other side).

In each switching mode, the power delivered can be calculated from the time at which the switching operation occurred. Each switching operation defines a new state of the converter, i.e. the path of the current flowing in the converter. The time interval between switching operations in two bridges shall be referred to as the switching interval T_nWhere n is 1 … number of switching intervals. The sum of all switching intervals is equal to a fraction of the switching period, typically half of the switching period. In this case, the switching intervals of the two half-cycles are the same, and the voltage and current change polarity in each half-cycle.

The switching interval is a function of the parameters d and g. Some switching intervals depend directly on d and g, others are a function of the current trajectory and can be determined by calculating when the current flowing through the diode crosses zero.

For each state, the current is varied by its switching interval T_nAnd in this state a function of the voltage and the inductance affecting the current.

Fig. 6 to 8 show the sequence of states for each switching mode and thus the overall shape of the voltage and current, and the timing of the switching operation between the states, i.e. the switching interval T₁,T₂,., which is a function of the parameters d and g. The effects of dead time and parasitic capacitance can be neglected in determining the switching intervals and the optimal parameters d and g.

Fig. 6 shows the shape of the voltage and current for Continuous Conduction Mode (CCM). Each half of the switching cycle comprises four switching intervals, each having a duration T₁、T₂、T₃、T₄Each duration corresponding to a different state of the converter. The current change Δ I in each interval_nAnd the corresponding values of the duration of the switching intervals are as follows (for simplicity, in this and other conduction modes, the formula shown is for the case when the transformer ratio is 1_sRequiring the use of a secondary voltage V on the reference primary side_s' instead).

Fig. 7 shows the shape of the voltage and current for the first discontinuous conduction mode (DCM 1). Each half of the switching cycle comprises three switching intervals, each having a duration T₁、T₂、T₃. The current change Δ I in each interval_nAnd the duration of the switching interval has the corresponding value:

fig. 8 shows the shape of the voltage and current for the second discontinuous conduction mode (DCM 2). Each half of the switching cycle comprises two switching intervals, each having a durationTime T₁、T₂. The current change Δ I in each interval_nAnd the duration of the switching interval has the corresponding value:

in summary, the following steps: in each conduction mode, the switching interval and current can be expressed as a function of the parameters d and g. The change in current in each state or switching interval can be summed to give current at each instant. Current traces (I) in fig. 6-8_LS) Based on the respective current and the current change Δ I over the respective time duration_n。

Based on this, in each state, the charge transferred is a function of the duration of that state and the current flowing in that state.

The charges transferred in each state are added to obtain the total charge Q transferred from the primary side to the secondary side in one switching period_p. The power P transferred from the primary side to the secondary side is a function of the charge and the primary voltage, wherein

P＝2fQ_pV_p

Where f is the switching frequency.

Thus, the transmitted power P can be expressed and calculated from the parameters d and g. The trajectory of the transformer current can also be calculated. Furthermore, the peak current and/or the RMS current and/or another characteristic value of the operation of the converter can be calculated and used as an objective function to be optimized. Instead, these two parameters allow two degrees of freedom given the desired power P to be transmitted and the objective function, and allow the determination of a solution containing the values of d and g that achieve the desired power and minimize the objective function.

With respect to fig. 6-8, the respective current traces (I) may be plotted_LS) The peak value of (a) is minimized, so that the average current remains constant over time.

Determining a solution containing the values of d and g may be accomplished by an optimization process. An analytical solution can be determined if the above function, which results in a function of P that depends on d and g, can be expressed algebraically. In other cases, numerical optimization may be used to determine the solution.

The result of the optimization may be expressed, for example, in the form of an equation for calculating the parameters d and g from the operating point or in the form of a look-up table.

The optimization to minimize peak current for both discontinuous conduction modes can be represented by the following equation for the control variables:

control variables in discontinuous conduction mode 1

In DCM1, parameters d and g are calculated according to the following formulas:

the value of g is negative in DCM1, which means that the phase of gate signal S6 leads the phase of gate signal S2, as shown in FIG. 9. This is in contrast to in CCM when g is positive and gate signal S6 lags gate signal S2.

The main part of the voltage and current traces is immediately visible from the timing of the switching operation. In the following, the situation that occurs when the transformer voltage on both sides is zero (phase a) is explained. During the phase just before this phase, S6 is off and S8 is on. The current decreases on both the primary side and the secondary side, and the current on the secondary side changes direction (indicated by an asterisk). Once the secondary current changes its direction, the current flows through the parasitic capacitances of S5 and S6. Once the parasitic capacitance of S6 is discharged, the body diode of S6 is activated, i.e., becomes conductive.

During phase a, the current on the secondary side is negative, which means that the capacitance of S2 on the primary side is not fully discharged. To address this problem, S8 is turned off and S6 is turned on, phase shifted with respect to the primary side switching operation. The switching cell containing S6 has been turned on in parallel with S6 by its body diode. In this manner, switch S6 is turned on under more or less zero voltage conditions.

The phase shift is considered negative because the turning on and off of S6 and S8 occurs when at least one switch on the primary side is turned on (i.e., to the left of D in fig. 9). In other words, when the switch S1 on the primary side is turned on, the switches S6 and S8 are turned on and off, respectively, before S1 is turned off.

During phase B, the parasitic capacitance of S8 is charged and the voltage will rise (negatively) until the current on the secondary side crosses zero. At this point, phase C begins.

During phase C, the secondary current now continues to increase in the positive direction and the parasitic capacitance of S8 discharges until the body diode of S8 becomes conductive, at which point phase D begins. When the diode of S8 is conducting, the secondary current flows in a direction that supports zero voltage switching on the primary side by the primary current increase.

In principle, all secondary MOSFETs may be turned off all the time in DCM 2. However, by switching S6 and S8 as suggested, the secondary MOSFET output capacitance can be prevented from transients (ring) due to transformer leakage inductance.

Control variables in discontinuous conduction mode 2

In DCM2, parameters d and g are calculated according to the following equations:

d＝0.5

typical waveforms of transformer voltage, current and gate signals in DCM2 are shown in FIG. 10. Note that the secondary transformer voltage V _ Ts (dashed line) is shown as having a lower value than the primary transformer voltage V _ Tp. However, the secondary voltage of the reference primary side is higher than the primary voltage, which is why the current is driven to zero when switching the switching cells S6 and S8 after the phase shift g.

Synchronous rectification

To reduce conduction losses, the switching cells operating as diodes (if they are active switching cells, like switches S5 and S7 in this embodiment) may be actively switched so that the secondary bridge circuit operates like a synchronous rectifier.

Reverse power flow

Due to the symmetry of the circuit, the same control method is used for reverse power transfer, but the primary and secondary quantities are interchanged. This means that Vp and Vs' must be interchanged, the control signals of S1 and S5, the control signals of S2 and S6, the control signals of S3 and S7, and the control signals of S4 and S8. An example of reverse power transmission in CCM is shown in fig. 11.

If power flows from the primary side to the secondary side, switches S5 and S7 are always open. Thus, if only unidirectional operation is desired, the switches S5 and S7 may be replaced with diodes, as shown in FIG. 12. The circuit may also be controlled in the manner described above.

Selection of switching units for active switches

The examples so far show that the secondary bridge circuit 43 is controlled by actively switching only the lower switch unit 49b or only the upper switch units 49a,49c and operating only the other switch units (upper or lower, respectively) as diodes. Alternatively, there may be embodiments wherein the secondary bridge circuit 43 is operated by actively switching only the upper and lower switching cells of one of the half- bridges 41, 42, wherein the upper and lower switching cells of the other of the half- bridges 41, 42 are operated only as diodes. In such an embodiment, substantially the same timing of the switching operations may be applied. For example, given the switching sequence of FIG. 3, where S6 and S8 are shown as switched, S5 may be switched instead of S8. To prevent punch-through, there must be a delay time between the switching of S5 and S6.

Fig. 13 shows a flow chart outlining the method for controlling a converter based on the above steps: the steps shown in the flow chart are repeated for each operating point depending on the primary and secondary voltages and the power to be transmitted. Usually, the series inductance L of the transformer_sAnd the switching frequency f is kept constant. These steps generate a conduction pattern to be applied and generate parameters d and g to be used in the conduction pattern. These steps may be performed once and the generated parameters may be applied as long as the operating point is unchanged, or may be repeatedly performed, regardless of whether the operating point has been changed. In factIn an embodiment, these steps are performed once per switching cycle.

Determining the conduction mode to be applied and the parameters d and g to be used comprises the steps of:

identify the direction of power flow, i.e. from primary to secondary, or vice versa. Typically, this is given by the monitor according to the selected operating mode of the converter, e.g. for charging a battery or by supplying power to the grid or another EV.

Depending on the power level, the conduction mode is determined.

For the determined conduction mode, the parameters d and g are calculated.

The switching signals are determined from the operating mode and the parameters d and g and used to control the switching units of the converter.

Although the present invention has been described in the current embodiment, it should be clearly understood that the present invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the claims.