Dual voltage automotive electrical system with sub-resonant DC-DC converter

• US 6,151,222 A
• Filed: 03/02/1999
• Issued: 11/21/2000
• Est. Priority Date: 03/02/1999
• Status: Expired due to Term

• Current Assignee: Delphi Technologies Ip Limited (BorgWarner Incorporated)
• Original Assignee: Delco Electronics Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Barrett, Alfred Henry
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Patel, Rajnikant B.
• Application Number:
  US09/261,878
• Time in Patent Office: 630 Days
• Field of Search: 363/16, 363/17, 363/98, 363/131, 363/132
• US Class Current: 363/16
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/33571 Half-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/33573 Full-bridge at primary 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

An improved dual voltage automotive electrical system in which low voltage loads are powered by a series resonant DC-DC converter operated at a fixed switching frequency below the resonant frequency of its tank circuit. With this arrangement, the converter provides a fixed conversion ratio from the regulated upper system voltage, and operates with the beneficial attributes of zero current switching and inherent overload protection. In a first embodiment, a transformer inductively couples the converter tank circuit to the low voltage loads, providing full input/output galvanic isolation. In a second embodiment, the converter is configured so that a portion of the power supplied to the low voltage loads is directly coupled from the upper system voltage source, with the remaining portion being coupled through the converter. In either embodiment, the accuracy of the conversion ratio and its load current independence are enhanced by a compounding coil having a load current dependent inductance coupled to the tank circuit.

Claims

1. A dual voltage automotive electrical system comprising in combination:

a regulated source of DC defining a first system voltage;

a series resonant converter coupled to said first system voltage for supplying power to a load circuit at a regulated second system voltage that is lower than said first system voltage, said converter including a series resonant tank circuit inductively coupled to said load circuit and comprising series resonant tank elements defining a dominant resonant frequency of said tank circuit, a transistor bridge circuit including alternately activated bridge transistors for supplying current from the regulated source of DC to the tank circuit, and a gate drive circuit for activating said bridge transistors at a fixed and predetermined switching frequency below said dominant resonant frequency of said, tank circuit to provide a fixed and predetermined voltage conversion ratio between said first and second system voltages.

2. The electrical system of claim 1, wherein the power supplied to said load circuit is inductively coupled from said tank circuit to said load circuit by an isolation transformer having a primary winding connected in said series tank circuit, and one or more secondary windings coupled to said load circuit through one or more rectifier elements.

3. The electrical system of claim 2, including a plurality of isolation transformers, each having a primary winding connected in said series tank circuit, and one or more secondary windings coupled to said load circuit through one or more rectifier elements.

4. The electrical system of claim 1, wherein the fixed and predetermined switching frequency of said gate drive circuit is about one-half of the dominant resonant frequency of said tank circuit.

5. The electrical system of claim 1, wherein said converter has an operating characteristic in which an output voltage supplied to said load circuit decreases with increasing current supplied to said load circuit, and said electrical system includes a compounding element inductively coupled to the load circuit and having an inductance that decreases with increasing current supplied to said load circuit by said converter, said compounding element being connected to said tank circuit so that its decreasing inductance overcomes said operating characteristic of said converter when the current supplied to said load circuit by said converter increases.

6. The electrical system of claim 5, wherein the power supplied to said load circuit is inductively coupled from said tank circuit to said load circuit by an isolation transformer having a primary winding connected in said series tank circuit, and said compounding element is connected in parallel with said primary winding.

7. The electrical system of claim 1, wherein said bridge transistors apply said first system voltage to said tank circuit such that all of the power supplied to said load circuit is coupled through the series tank circuit of said converter.

8. The electrical system of claim 1, wherein said bridge transistors are connected in series with said load circuit, and apply only a portion of said first system voltage to said tank circuit, so that a first portion of the power supplied to said load circuit is coupled through the series tank circuit of said converter, and a second portion of the power supplied to said load circuit is coupled directly from said regulated source of DC.

9. The electrical system of claim 8, wherein said first portion of the power supplied to said load circuit is inductively coupled from said tank circuit to said load circuit by at least one isolation transformer having a primary winding connected in said series tank circuit, and one or more secondary windings coupled to said load circuit through one or more rectifier elements, the primary and secondary windings having a turns ratio that determines an output voltage of the power supplied to said load, and relative magnitudes of said first and second portions.

10. The electrical system of claim 8, wherein said converter has an operating characteristic in which an output voltage supplied to said load circuit decreases with increasing current supplied to said load circuit, and said electrical system includes a compounding element inductively coupled to the load circuit and having an inductance that decreases with increasing current supplied to said load circuit by said converter, said compounding element being connected to said tank circuit so that its decreasing inductance overcomes said operating characteristic of said converter when the current supplied to said load circuit by said converter increases, whereby the power supplied to said load circuit has a voltage that is substantially independent of the current supplied to said load circuit by said converter.