Bi-directional DC/DC converter and control method therefor

• US 6,437,462 B1
• Filed: 12/10/2001
• Issued: 08/20/2002
• Est. Priority Date: 12/10/2001
• Status: Expired due to Term

• Current Assignee: Delphi Technologies Ip Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Mozipo, Aurelien T., Sriram, Tillasthanam V., Maple, Robert
• Primary Examiner(s): Riley, Shawn
• Application Number:
  US10/012,836
• Time in Patent Office: 253 Days
• Field of Search: 307/44, 307/45, 307/46, 307/75, 307/80, 307/86, 307/87
• US Class Current: 307/75
• 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: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Method and system for bi-directionally controlling power flow between two separate direct current power sources in a multi-stage power converter system are provided. The method allows providing at least first and second power converter stages coupled in parallel circuit to one another. The method further allows providing a first switching controller coupled to selectively actuate a pair of switching devices in the first power converter stage, and a second switching controller coupled to selectively actuate a pair of switching devices in the second power converter stage. One of the first and second switching controllers is selected as a master controller, and the other one of the first and second switching controllers is selected as a slave controller. An average voltage measurement is determined at a respective node of each the power converter stages. A compensating signal is generated based on the difference of the average voltage measurements at the respective nodes of each of the power converter stages. The compensating signal is applied to the slave switching controller so that the pair of power switching devices coupled to that slave switching controller is selectively actuated to have a respective on and off duty cycle. The duty cycle imparted by the slave controller is adjustable in response to the compensating signal relative to the duty cycle imparted by the master controller to the pair of power switching devices coupled thereto in order to avoid current imbalance between the power converter stages.

Claims

1. A method for bi-directionally controlling power flow between at least two separate direct current power sources in a multi-stage power converter system, the method comprising:

providing at least first and second power converter stages coupled in parallel circuit to one another;

providing a first switching controller coupled to selectively actuate a pair of switching devices in the first power converter stage;

providing a second switching controller coupled to selectively actuate a pair of switching devices in the second power converter stage, with one of the first and second switching controllers selected as a master controller, and the other one of the first and second switching controllers selected as a slave controller;

determining an average voltage measurement at a respective node of each the power converter stages;

generating a compensating signal based on the difference of the average voltage measurements at the respective nodes of each of the power converter stages; and

applying the compensating signal to the slave switching controller so that the pair of power switching devices coupled to that slave switching controller is selectively actuated to have a respective on and off duty cycle, the duty cycle imparted by the slave controller being adjustable in response to the compensating signal relative to the duty cycle imparted by the master controller to the pair of power switching devices coupled thereto to avoid current imbalance between the power converter stages.

2. The method of claim 1 wherein the first and second switching controllers comprise respective pulse-width modulation controllers.

3. The method of claim 2 wherein determining the average voltage measurement at each respective node of the power converter stages comprises coupling a respective averaging filter to receive a voltage signal from each respective node.

4. The method of claim 3 wherein generating the compensating signal comprises differentially combining the output signal from each averaging filter to supply a resultant signal, and applying the resultant signal to a compensating circuit configured to generate the compensating signal based on the magnitude and polarity of the resultant signal.

5. The method of claim 1 wherein one of the power sources comprises a power source configured to supply a higher voltage relative to the other power source.

6. The method of claim 5 wherein one of the power switching devices in each power converter stage is configured to operate in a first mode of power conversion in pulse-width modulation switching condition, and the other one of the power switching devices is configured to operate, at least part of the time, in a freewheeling condition, and wherein in a second power conversion mode the one power switching device is configured to operate, at least part of the time, in the freewheeling condition, and the other power switching device is configured to operate in the pulse-width modulation switching condition.

7. The method of claim 6 wherein the first mode of power conversion comprises a step-up mode of power conversion, and the second mode of power conversion comprises a step-down mode of power conversion.

8. The method of claim 7 further comprising monitoring a predefined electrical parameter indicative of current passing in a first direction through the freewheeling device and setting that device to an on-state during the freewheeling condition, and to an off-state when current flow reversal relative to that first direction is determined for that switching device.

9. The method of claim 1 further comprising coupling to at least one of the power sources a circuit comprising a pair of power switching devices connected in series circuit and configured to bi-directionally isolate and protect the converter and/or power source under predefined fault conditions.

10. The method of claim 1 further comprising coupling to each of the power sources a circuit comprising a respective power switching device configured to bi-directionally isolate and protect the converter and/or power sources under predefined fault conditions.

11. A multi-stage power converter system for bi-directionally controlling power flow between at least two separate direct current power sources, the power converter system comprising:

at least first and second power converter stages coupled in parallel circuit to one another;

a first switching controller coupled to selectively actuate a pair of switching devices in the first power converter stage;

a second switching controller coupled to selectively actuate a pair of switching devices in the second power converter stage, with one of the first and second switching controllers selected as a master controller, and the other one of the first and second switching controllers selected as a slave controller;

a feedback controller configured to avoid current imbalance between the power converter stages by;

determining an average voltage measurement at a respective node of each the power converter stages;

generating a compensating signal based on the difference of the average voltage measurements at the respective nodes of each of the power converter stages; and

applying the compensating signal to the slave switching controller so that the pair of power switching devices coupled to that slave switching controller is selectively actuated to have a respective on and off duty cycle, the duty cycle imparted by the slave controller being adjustable in response to the compensating signal relative to the duty cycle imparted by the master controller to the pair of power switching devices coupled thereto, thus avoiding current imbalance between the power converter stages.

12. The power converter system of claim 11 wherein the first and second switching controllers comprise respective pulse-width modulation controllers.

13. The power converter system of claim 12 further comprising a respective averaging filter coupled to receive a voltage signal from each respective node, each filter configured to determine the average voltage measurement at each respective node of the power converter stages.

14. The power converter system of claim 13 further comprising a signal combiner configured to differentially combine the output signal from each averaging filter to supply a resultant signal, the signal combiner coupled to apply the resultant signal to a compensating circuit configured to generate the compensating signal based on the magnitude and polarity of the resultant signal.

15. The power converter system of claim 11 wherein one of the power sources comprises a power source configured to supply a higher voltage relative to the other power source.

16. The power converter system of claim 15 wherein one of the power switching devices in each power converter stage is configured to operate in a first mode of power conversion in pulse-width modulation switching condition, and the other one of the power switching devices is configured to operate, at least part of the time, in a freewheeling condition, and wherein in a second power conversion mode the one power switching device is configured to operate, at least part of the time, in the freewheeling condition, and the other power switching device is configured to operate in the pulse-width modulation switching condition.

17. The power converter system of claim 16 wherein the first mode of power conversion comprises a step-up mode of power conversion, and the second node of power conversion comprises a step-down mode of power conversion.

18. The power converter system of claim 17 further comprising a circuit configured to monitor a predefined electrical parameter indicative of current passing in a first direction through the freewheeling device, the circuit further configured to set that device to an on-state during the freewheeling condition, and to an off-state when current flow reversal relative to that first direction is determined for that switching device.

19. The power converter system of claim 11 further comprising a circuit coupled to at least one of the power sources and including a pair of power switching devices connected in series circuit and configured to bi-directionally isolate and protect the converter and/or power source under predefined fault conditions.

20. The power converter system of claim 11 further comprising a circuit having respective circuit stages coupled to a respective one of the power sources, each circuit stage including a respective power switching device and, in combination, configured to bi-directionally isolate and protect the converter and/or power sources under predefined fault conditions.

21. A multi-stage power converter system for bi-directionally controlling power flow between at least two separate direct current power sources, the power converter system comprising:

at least first and second power converter stages coupled in parallel circuit to one another;

a first switching controller coupled to selectively actuate a pair of switching devices in the first power converter stage;

a second switching controller coupled to selectively actuate a pair of switching devices in the second power converter stage, with one of the first and second switching controllers selected as a master controller, and the other one of the first and second switching controllers selected as a slave controller;

a feedback controller configured to avoid current imbalance between the power converter stages, the feedback controller comprising;

a circuit configured to determine an average voltage measurement at a respective node of each the power converter stages;

a compensator configured to generate a compensating signal based on the difference of the average voltage measurements at the respective nodes of each of the power converter stages, the compensator being coupled to the slave switching controller to supply the compensating signal thereto so that the pair of power switching devices coupled to that slave switching controller is selectively actuated to have a respective on and off duty cycle, the duty cycle imparted by the slave controller being adjustable in response to the compensating signal relative to the duty cycle imparted by the master controller to the pair of power switching devices coupled thereto, thus avoiding current imbalance between the power converter stages.