CRITICAL MODE CONTROL DISCONTINUOUS MODE BOOST-BUCK CHARGER

• US 20130038273A1
• Filed: 04/27/2012
• Published: 02/14/2013
• Est. Priority Date: 04/27/2011
• Status: Active Grant

• Current Assignee: EEtrex Inc. (Methode Electronics Incorporated)
• Original Assignee: EEtrex Inc. (Methode Electronics Incorporated)
• Inventors: Houghton, Brian
• Granted Patent: US 8,896,263 B2
• Time in Patent Office: Days
• US Class Current: 320/107
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

Aspects of the present disclosure involve a charging system that provides a consistent specified charge power to a battery. Aspects of the disclosure also involve a bi-directional inverter charger system using boost and buck topologies substantially similar to buck and boost topologies for the charging system.

Claims

1. An apparatus for charging an energy storage system comprising:

a rectifier configured to receive an alternating current supply voltage and provide a full wave rectified direct current voltage;

a boost circuit receiving the full wave rectified direct current voltage, the boost circuit including a boost inductor coupled between the rectifier and a boost switch configuration, the boost switch across the rectifier, the boost switch configuration alternating between charging the inductor in an on state and allowing the inductor to boost the full wave rectified direct current voltage to a boosted voltage and charge a link capacitor provided in parallel with the boost switch; and

a buck circuit configured to receive the boosted voltage from the link capacitor, the buck circuit configured to provide a substantially steady specified charge power to at least one battery, the buck circuit including a buck inductor, a buck diode and a buck switch configuration, the buck switch configuration configured to turn on to charge the boost inductor and turn off to provide a charge current to the battery, the buck switch configuration receiving a buck pulse width modulated control signal to provide the specified charge power to the battery.

2. The apparatus of claim 1 wherein the boost inductor is a low permeability inductor with a two turn secondary winding and a 22 turn primary winding.

3. The apparatus of claim 1 further comprising a pulse width modulation controller that provides a pulse width modulated control signal to the boost switch configuration, the control signal configured to deplete a boost inductor core of the boost inductor to about 0 before turning on the boost switch configuration to charge the boost inductor.

4. The apparatus of claim 3 further comprising a pulse width modulate control signal to the boost switch configuration, the control signal being of variable width depending on a voltage level of the full wave rectified direct current voltage, the width being narrower at line peak voltage and being wider away from the peak voltage, the control signal also depending on a specified charge voltage of the link capacitor.

5. The apparatus of claim 4 further wherein the pulse width modulation controller receives a feedback signal from a secondary winding to hold gates of the boost switches while flyback voltage is present in the secondary winding.

6. The apparatus of claim 1 further comprising a boost diode between the boost inductor and the link capacitor, the boost diode preventing the link capacitor from discharging through the boost switch configuration.

7. The apparatus of claim 6 further comprising a precharge relay in series with the boost inductor and a precharge resistor in communication with the link capacitor, the precharge relay configured to shunt current through the precharge resistor to charge the link capacitor, the precharge relay further configured to close and allow current through the boost inductor and by-pass the precharge resistor.

8. The apparatus of claim 7 further comprising a wrap-around diode connected between the precharge relay and the link capacitor, the wrap-around diode providing protection in the event of a power surge.

9. The apparatus of claim 1 wherein a pulse width modulated control signal is provided to the boost switch configuration, the boost switch configuration including at least one MOSFET, the PWM control signal operating at a frequency to substantially prevent the at least one MOSFET from operating in a linear region of the MOSFET.

10. The apparatus of claim 1 wherein the buck circuit is operated in a continuous conduction mode.

11. The apparatus of claim 1 further comprising at least one current sense configured to measure current flowing to and from the at least one battery such that a charge power to the at least one battery is held substantially constant regardless of the at least one battery voltage.

12. The apparatus of claim 1 wherein:

the boost circuit comprises means for boosting a DC rail voltage to the link capacitor, and

the buck circuit comprises means for regulating the charge power to the battery.

13. The apparatus of claim 1 wherein:

the rectifier is a bride rectifier including a plurality of MOSFETs, the bridge rectifier configured to receive an alternating current supply voltage and provide a full wave rectified direct current voltage or configured to deliver a discharge current to the alternating current supply;

the boost circuit connected to the bridge rectifier in charge mode or to a battery in discharge mode, and

the buck circuit connected to the boost circuit in charge mode or to the bridge rectifier in discharge mode.