Power distribution architecture with series-connected bus converter

• US 10,199,950 B1
• Filed: 07/02/2013
• Issued: 02/05/2019
• Est. Priority Date: 07/02/2013
• Status: Active Grant

• Current Assignee: Vicor Corporation
• Original Assignee: VLT Incorporated (Vicor Corporation)
• Inventors: Vinciarelli, Patrizio, D'Amico, Andrew
• Primary Examiner(s): Chang, Joseph
• Application Number:
  US13/933,252
• Time in Patent Office: 2,044 Days
• Field of Search: 307 82
• CPC Class Codes: H02M 1/0058 by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 1/0093 wherein the output is created by adding a regulated voltage to or subtracting it from an unregulated input
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 3/33561 having more than one ouput with independent control
• CPC Class Codes: H02M 3/33576 having at least one active switching element at the secondary side of an isolation transformer
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

Apparatus for power conversion are provided. One apparatus includes a power converter including an input circuit and an output circuit. The power converter is configured to receive power from a source for providing power at a DC source voltage V_S. The power converter is adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio K_DC=V_OUT/V_IN at an output current, wherein V_IN is an input voltage and V_OUT is an output voltage. The input circuit and at least a portion of the output circuit are connected in series across the source, such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1.

Claims

1. An apparatus comprising:

a power distribution system comprising a source for providing power at a DC source voltage V_S;

a bus converter comprising an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

a power distribution bus connected to distribute power from the output circuit of the bus converter at the output voltage V_OUT; and

a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter;

wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are galvanically connected in series across the source such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1;

wherein the bus converter comprises an inductive component and one or more power switches in the input circuit, the output circuit, or both; and

wherein a current flowing in the inductive component charges and discharges capacitances in the bus converter reducing a voltage across said one or more switches prior to turning ON said one or more switches.

2. The apparatus of claim 1, wherein both the input circuit and the output circuit comprise full-bridge circuits, wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns.

3. The apparatus of claim 1, wherein the output circuit comprises a center-tap output circuit comprising two windings, wherein each winding comprises a same number of turns, and wherein N is equal to approximately 2, such that the input voltage V_IN is approximately equal to the DC source voltage V_S minus 2 times the output voltage V_OUT.

4. The apparatus of claim 1, wherein the bus converter is configured to receive an input voltage V_IN at the input circuit characterized by a first polarity and output an output voltage V_OUT from the output circuit characterized by a second polarity, the second polarity being opposite the first polarity.

5. The apparatus of claim 1, wherein the bus converter comprises:

a transformer, and a resonant circuit including the transformer having a characteristic resonant frequency and period, the input circuit including two or more primary switches connected to drive the resonant circuit and the output circuit being connected to receive power from the transformer; and

a switch controller adapted to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristics resonant period, during which one or more of the primary switches are ON and power is transferred from the input to the output via the transformer.

6. The apparatus of claim 1, wherein the bus converter is a self-contained assembly adapted to be installed as a unit.

7. The apparatus of claim 1, further comprising a circuit board, wherein the bus converter and at least one regulator are assembled to the circuit board, and the regulator is configured to supply power to an integrated circuit.

8. The apparatus of claim 1, further comprising a clamp circuit connected to prevent the output voltage, V_OUT, from exceeding a predetermined level.

25. The apparatus of claim 1 wherein the input circuit comprises a primary winding and primary switches connected to the primary winding, the output circuit comprises a secondary winding and secondary switches connected to the secondary winding, and a controller for operating the switches in a series of converter operating cycles, wherein the primary and secondary windings are connected in series during at least a portion of each converter operating cycle.

28. The apparatus of claim 1 wherein the voltage across said one or more power switches is reduced to essentially zero volts prior to turning ON said one or more switches.

9. An apparatus comprising:

a power converter comprising an input circuit and an output circuit, wherein the power converter is configured to receive power from a power distribution system comprising a source for providing power at a DC source voltage V_S, the power converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the power converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN, wherein the power converter further comprises;

a series connection between the input circuit of the power converter and at least a portion of the output circuit of the power converter across the source, such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1;

wherein the power converter comprises an inductive component and one or more power switches in the input circuit, the output circuit, or both; and

wherein a current flowing in the inductive component charges and discharges capacitances in the power converter reducing a voltage across said one or more switches prior to turning ON said one or more switches.

10. The apparatus of claim 9, wherein both the input circuit and the output circuit comprise full-bridge circuits, wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns.

11. The apparatus of claim 9, wherein the output circuit comprises a center-tap output circuit comprising two windings, wherein each winding comprises a same number of turns, and wherein N is approximately equal to 2, such that the input voltage V_IN is approximately equal to the DC source voltage V_S minus 2 times the output voltage V_OUT.

12. The apparatus of claim 9, wherein the power converter is configured to receive an input voltage V_IN at the input circuit characterized by a first polarity and output an output voltage V_OUT from the output circuit characterized by a second polarity, the second polarity being opposite the first polarity.

13. The apparatus of claim 9, wherein the power converter comprises:

a transformer, and a resonant circuit including the transformer having a characteristic resonant frequency and period, the input circuit including two or more primary switches connected to drive the resonant circuit and the output circuit being connected to receive power from the transformer; and

a switch controller adapted to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristics resonant period, during which one or more of the primary switches are ON and power is transferred from the input to the output via the transformer.

14. The apparatus of claim 9, wherein the power converter is part of a bus converter that is a self-contained assembly adapted to be installed as a unit.

15. The apparatus of claim 9, further comprising a circuit board, and wherein the power converter is configured to supply power to a plurality of regulators over a power distribution bus, the regulators disposed at a distance to the power converter, and wherein at least one of the regulators is assembled to the circuit board and configured to supply power to an integrated circuit.

26. The apparatus of claim 9 wherein the input circuit comprises a primary winding and primary switches connected to the primary winding, the output circuit comprises a secondary winding and secondary switches connected to the secondary winding, and a controller for operating the switches in a series of converter operating cycles, wherein the primary and secondary windings are connected in series during at least a portion of each converter operating cycle.

16. An apparatus comprising:

a bus converter comprising an input circuit and an output circuit, wherein the bus converter is configured to receive power from a power distribution system comprising a source for providing power at a DC source voltage V_S, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

a power distribution bus connected to distribute power from the output circuit of the bus converter at the output voltage V_OUT; and

a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter;

wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are connected in series across the source such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1;

wherein the bus converter comprises an inductive component and one or more power switches in the input circuit, the output circuit, or both; and

wherein a current flowing in the inductive component charges and discharges capacitances in the bus converter reducing a voltage across said one or more switches prior to turning ON said one or more switches.

17. The apparatus of claim 16, wherein both the input circuit and the output circuit comprise full-bridge circuits, wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns.

18. The apparatus of claim 16, wherein the output circuit comprises a center-tap output circuit comprising two windings, wherein each winding comprises a same number of turns, and wherein N is equal to 2, such that the input voltage V_IN is approximately equal to the DC source voltage V_S minus 2 times the output voltage V_OUT.

19. The apparatus of claim 16, wherein the bus converter is a self-contained assembly adapted to be installed as a unit.

20. The apparatus of claim 16, wherein the bus converter is configured to receive an input voltage V_IN at the input circuit characterized by a first polarity and output an output voltage V_OUT from the output circuit characterized by a second polarity, wherein the first polarity is opposite the second polarity.

21. The apparatus of claim 16, wherein the bus converter comprises:

a transformer, and a resonant circuit including the transformer having a characteristic resonant frequency and period, the input circuit including two or more primary switches connected to drive the resonant circuit and the output circuit being connected to receive power from the transformer; and

a switch controller adapted to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristics resonant period, during which one or more of the primary switches are ON and power is transferred from the input to the output via the transformer.

27. The apparatus of claim 16 wherein the input circuit comprises a primary winding and primary switches connected to the primary winding, the output circuit comprises a secondary winding and secondary switches connected to the secondary winding, and a controller for operating the switches in a series of converter operating cycles, wherein the primary and secondary windings are connected in series during at least a portion of each converter operating cycle.

22. An apparatus comprising:

an intermediate bus architecture power distribution system for an electrical system comprising a source for providing power at a DC source voltage;

a circuit board comprising a bus converter, the bus converter comprising an input circuit, the input circuit comprising a primary transformer winding, the bus converter further comprising an output circuit, the output circuit comprising a secondary transformer winding, wherein the primary and secondary transformer windings are galvanically connected in series, and wherein the bus converter is configured to provide power to a power distribution bus that is not galvanically isolated from the source; and

the circuit board further comprising a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter.

23. The apparatus of claim 22, wherein the bus converter is adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

and

wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are connected such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1.

24. The apparatus of claim 22, wherein the bus converter is a self-contained assembly adapted to be installed as a unit.

39. The apparatus of claim 22 wherein the bus converter comprises an inductive component and one or more power switches in the input circuit, the output circuit, or both, and wherein a current flowing in the inductive component charges and discharges capacitances in the bus converter reducing a voltage across said one or more switches prior to turning ON said one or more switches.

40. The apparatus of claim 22 wherein at least one of the regulators is assembled to the circuit board and configured to supply power to an integrated circuit.

29. An apparatus comprising:

a power distribution system comprising a source for providing power at a DC source voltage V_S;

a bus converter comprising an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

a power distribution bus connected to distribute power from the output circuit of the bus converter at the output voltage V_OUT; and

a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter;

wherein the input circuit of the bus converter and the output circuit of the bus converter are galvanically connected; and

wherein the bus converter comprises an inductive component and one or more power switches in the input circuit or output circuit or both; and

wherein a current flowing in the inductive component charges and discharges capacitances in the converter reducing a voltage across said one or more switches prior to turn ON of said one or more switches.

30. The apparatus of claim 29 wherein the voltage across said one or more switches is reduced to essentially zero volts prior to turn ON of said one or more switches.

31. An apparatus comprising:

a power distribution system comprising a source for providing power at a DC source voltage V_S;

a bus converter comprising an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

a power distribution bus connected to distribute power from the output circuit of the bus converter at the output voltage V_OUT; and

a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter;

wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns; and

wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are connected in series across the source such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1.

32. An apparatus comprising:

a power distribution system comprising a source for providing power at a DC source voltage V_S;

a bus converter comprising an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

a power distribution bus connected to distribute power from the output circuit of the bus converter at the output voltage V_OUT; and

a plurality of regulators, wherein each regulator comprises a regulator input connected to the power distribution bus to receive power from the output circuit of the bus converter and a regulator output connected to supply power to a respective load, the plurality of regulators each being separated by a distance from the bus converter;

wherein the input circuit comprises a winding having a first number of turns, wherein the output circuit comprises a winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns; and

wherein the input circuit of the bus converter and the output circuit of the bus converter are galvanically connected.

33. An apparatus comprising:

a bus converter comprising an input circuit and an output circuit, the bus converter being adapted to convert power from the input circuit to the output circuit at a substantially fixed voltage transformation ratio, K_DC, at an output current, wherein an input voltage V_IN is applied to the input circuit and an output voltage V_OUT is produced by the output of the bus converter, and wherein the substantially fixed voltage transformation ratio can be represented as K_DC=V_OUT/V_IN;

wherein the input circuit of the bus converter and the output circuit of the bus converter are galvanically connected; and

wherein the bus converter comprises an inductive component and one or more power switches in the input circuit or output circuit or both; and

wherein a current flowing in the inductive component charges and discharges capacitances in the converter reducing a voltage across said one or more switches prior to turn ON said one or more switches.

34. The apparatus of claim 33, wherein the bus converter comprises:

a transformer, and a resonant circuit including the transformer having a characteristic resonant frequency and period, the input circuit including two or more primary switches connected to drive the resonant circuit and the output circuit being connected to receive power from the transformer; and

a switch controller adapted to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristics resonant period, during which one or more of the primary switches are ON and power is transferred from the input to the output via the transformer.

35. The apparatus of claim 33 wherein the voltage across said one or more switches is reduced to essentially zero volts prior to turn ON of said one or more switches.

36. The apparatus of claim 33 wherein the input circuit of the bus converter and at least a portion of the output circuit of the bus converter are connected in series across the source such that an absolute value of the input voltage V_IN applied to the input circuit is approximately equal to the absolute value of the DC source voltage V_S minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1.

37. The apparatus of claim 33, wherein the input circuit comprises a first winding having a first number of turns, wherein the output circuit comprises a second winding having a second number of turns, and wherein the voltage transformation ratio is a function of a ratio of the first number of turns to the second number of turns.

38. The apparatus of claim 37, wherein at least a portion of the input circuit of the bus converter is connected in series with at least a portion of the output circuit of the bus converter such that an absolute value of a voltage applied to the first winding is approximately equal to the absolute value of the input voltage, V_IN, minus a number N times the absolute value of the output voltage V_OUT, where N is at least 1.