Method and apparatus for controlling a DC/DC power converter

• US 10,541,614 B1
• Filed: 05/08/2019
• Issued: 01/21/2020
• Est. Priority Date: 05/08/2019
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Gagas, Brent S., Welchko, Brian A.
• Primary Examiner(s): Berhane, Adolf D
• Assistant Examiner(s): Demisse, Afework S
• Application Number:
  US16/406,598
• Time in Patent Office: 258 Days
• CPC Class Codes: G05F 1/10 Regulating voltage or current G05F1/02 takes precedence; for electric railways B60M3/02
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• CPC Class Codes: H02M 3/1586 switched with a phase shift, i.e. interleaved

Abstract

A DC-DC power converter is described, and includes switched inductance circuits arranged in parallel, current sensors disposed to monitor one of the switched inductance circuits, and a controller. The DC-DC power converter supplies electric power originating from a DC power source to a high-voltage bus. Control and operation includes determining a desired control mode for operating the DC-DC power converter, wherein the desired control mode includes one of a voltage control mode and a current control mode. A desired voltage and a desired differential current for operating the DC-DC power converter are determined based upon the desired control mode. A desired current for operating the DC-DC power converter is determined based upon the desired differential current. Operation of the DC-DC power converter is controlled in the desired control mode based upon the desired voltage and the desired current.

Claims

1. A method for controlling a DC-DC power converter arranged to supply electric power originating from a DC power source to a high-voltage bus, the method comprising:

determining a desired control mode for operating the DC-DC power converter, wherein the desired control mode comprises one of a voltage control mode and a current control mode;

determining a desired voltage for operating the DC-DC power converter based upon the desired control mode;

determining a desired differential current for operating the DC-DC power converter based upon the desired control mode;

determining a desired current for operating the DC-DC power converter based upon the desired differential current and the desired voltage; and

controlling operation of the DC-DC power converter in the desired control mode based upon the desired voltage and the desired current.

2. The method of claim 1, wherein determining the desired voltage for operating the DC-DC power converter based upon the desired control mode comprises setting the desired voltage equal to a feedback voltage when the desired control mode is the current control mode.

3. The method of claim 1, wherein determining the desired voltage for operating the DC-DC power converter based upon the desired control mode comprises executing a voltage command state filter to determine the desired voltage when the desired control mode is the voltage control mode.

4. The method of claim 1, wherein the desired voltage is subjected to a minimum saturation limit and a maximum saturation limit.

5. The method of claim 1, wherein determining the desired differential current for operating the DC-DC power converter based upon the desired control mode comprises determining a first desired differential current based upon a difference between the desired voltage and a feedback voltage when the desired control mode is the voltage control mode.

6. The method of claim 5, further comprising executing an anti-windup function to control the first desired differential current when the first desired differential current exceeds a saturation limit.

7. The method of claim 5, further comprising integrating the first desired differential current to determine the desired current when the desired control mode comprises the voltage control mode.

8. The method of claim 1, wherein determining the desired differential current for operating the DC-DC power converter based upon the desired control mode comprises determining a second desired differential current based upon a difference between a previously determined desired current and a current request when the desired control mode is the current control mode.

9. The method of claim 8, further comprising integrating the second desired differential current to determine the desired current when the desired control mode comprises the current control mode and when the desired voltage has not reached either a maximum saturation limit or a minimum saturation limit.

10. The method of claim 8, further comprising:

determining a first desired differential current based upon a difference between the desired voltage and a monitored voltage;

selecting a maximum of the first desired differential current and the second desired differential current; and

integrating the maximum of the first and second desired differential currents to determine the desired current when the desired control mode comprises the current control mode and when the desired voltage has reached the maximum saturation limit.

11. The method of claim 8, further comprising:

determining a first desired differential current based upon a difference between the desired voltage and a monitored voltage;

selecting a minimum of the first desired differential current and the second desired differential current; and

integrating the minimum of the first and second desired differential currents to determine the desired current when the desired control mode comprises the current control mode and when the desired voltage has reached the minimum saturation limit.

12. A DC-DC power converter arranged to supply electric power originating from a DC power source to a high-voltage bus, comprising:

a plurality of interleaved switched inductance circuits, a bulk capacitor, and a HWIO (“

hardware input/output”

) circuit including a gate driver circuit and an electrical interface circuit;

wherein each of the interleaved switched inductance circuits includes an inductor, a diode and a power semiconductor switch, and a current sensor;

wherein the DC-DC power converter is operated at a fixed frequency with a preset cycle time;

wherein the plurality of switched inductance circuits are operated with offsets in phase during each cycle period;

and

a controller, in communication with the HWIO circuit, the controller including a memory device including an instruction set, the instruction set executable to;

determine a desired control mode for operating the DC-DC power converter, wherein the desired control mode comprises one of a voltage control mode and a current control mode;

determine a desired voltage for operating the DC-DC power converter based upon the desired control mode;

determine a desired differential current for operating the DC-DC power converter based upon the desired control mode;

determine a desired current for operating the DC-DC power converter based upon the desired differential current and the desired voltage; and

control operation of the DC-DC power converter in the desired control mode based upon the desired voltage and the desired current.

13. The DC-DC power converter of claim 12, wherein the instruction set executable to determine the desired voltage for operating the DC-DC power converter based upon the desired control mode comprises the instruction set executable to set the desired voltage equal to a feedback voltage when the desired control mode is the current control mode.

14. The DC-DC power converter of claim 12, wherein the instruction set executable to determine the desired voltage for operating the DC-DC power converter based upon the desired control mode comprises the instruction set executable to execute a voltage command state filter to determine the desired voltage when the desired control mode is the voltage control mode.

15. The DC-DC power converter of claim 12, wherein the desired voltage is subjected to a minimum saturation limit and a maximum saturation limit.

16. The DC-DC power converter of claim 12, wherein the instruction set executable to determine the desired differential current for operating the DC-DC power converter based upon the desired control mode comprises the instruction set executable to determine a first desired differential current based upon a difference between the desired voltage and a feedback voltage when the desired control mode is the voltage control mode.

17. The DC-DC power converter of claim 16, further comprising the instruction set executable to execute an anti-windup function to control the first desired differential current when the first desired differential current exceeds a saturation limit.

18. The DC-DC power converter of claim 16, further comprising the instruction set executable to integrate the first desired differential current to determine the desired current when the desired control mode comprises the voltage control mode.

19. The DC-DC power converter of claim 12, wherein the instruction set executable to determine a desired differential current for operating the DC-DC power converter based upon the desired control mode comprises the instruction set executable to determine a second desired differential current based upon a difference between a previously determined desired current and a current request when the desired control mode is the current control mode.

20. The DC-DC power converter of claim 19, further comprising the instruction set executable to integrate the second desired differential current to determine the desired current when the desired control mode comprises the current control mode and when the desired voltage has not reached either a maximum saturation limit or a minimum saturation limit.