Method and apparatus to provide power conversion with high power factor

• US 9,660,520 B2
• Filed: 04/08/2014
• Issued: 05/23/2017
• Est. Priority Date: 04/09/2013
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Lim, Seungbum, Otten, David M., Perreault, David J.
• Primary Examiner(s): Mehari, Yemane
• Application Number:
  US14/758,033
• Publication Number:
  US 20150357912A1
• Time in Patent Office: 1,141 Days
• Field of Search: 363 16, 363 37, 363 44, 363123-127, 363143
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/0074 Plural converter units whose inputs are connected in series
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: H02M 1/4241 using a resonant converter
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 3/33569 having several active switching elements H02M3/3353 takes precedence
• CPC Class Codes: H02M 7/06 using discharge tubes without control electrode or semiconductor devices without control electrode
• 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

A power converter circuit rectifies a line voltage and applies the rectified voltage to a stack of capacitors. Voltages on the capacitors are coupled to a plurality of regulating converters to be converted to regulated output signals. The regulated output signals are combined and converted to a desired DC output voltage of the power converter. Input currents of the regulating converters are modulated in a manner that enhances the power factor of the power converter.

Claims

1. A power converter circuit comprising:

a line frequency rectifier circuit having an input and an output wherein in response to an alternating current (ac) input voltage of the power converter circuit being provided to the input of said line frequency rectifier circuit, said line frequency rectifier circuit rectifies the ac input voltage and provides a rectified output voltage at the output thereof;

a plurality of capacitors coupled to form a stack of capacitors, the stack of capacitors coupled to the output of the line frequency rectifier circuit so as to receive an output signal of the line frequency rectifier circuit such that a total voltage across the stack of capacitors is equal to a voltage at the output of the line frequency rectifier circuit;

a set of regulating converters coupled to the stack of capacitors, such that each regulating converter in the set of regulating converters is capable of drawing current from a corresponding one of the plurality of capacitors which form the stack of capacitors and generating a regulated voltage output power at an output thereof; and

a power combining converter circuit coupled to receive and combine the regulated voltage output powers generated by the set of regulating converters to convert the combined power to a desired direct current (dc) output voltage.

2. The power converter circuit of claim 1, further including:

a controller configured to controllably modulate input current of one or more of the regulating converters in the set of regulating converters in a manner that results in a power factor at the ac input of the power converter circuit that is greater than or equal to 0.8 for at least some operating conditions.

3. The power converter circuit of claim 1, further including:

a controller configured to controllably modulate input current of all of the regulating converters in the set of regulating converters in a manner that enhances power factor at the ac input of the power converter circuit.

4. The power converter circuit of claim 1, wherein:

the set of regulating converters includes at least one inverted resonant-transition buck converter or synchronous resonant-transition buck converter.

5. The power converter circuit of claim 1, wherein:

the set of regulating converters includes at least one buck converter.

6. The power converter circuit of claim 1, wherein:

the stack of capacitors buffers a substantial portion of a twice-line-frequency energy.

7. The power converter circuit of claim 6, wherein:

one or more capacitors in the stack of capacitors has a capacitance value that is substantially greater than capacitors in the stack of capacitors not including the one or more capacitors, wherein the one or more capacitors buffers a greater portion of the twice-line frequency than the capacitors in the stack of capacitors not including the one or more capacitors.

8. The power converter circuit of claim 1, wherein:

the power combining converter circuit includes a switched capacitor circuit.

9. The power converter circuit of claim 1, wherein:

the power combining converter circuit provides electrical isolation.

10. The power converter circuit of claim 1, wherein:

the power combining converter circuit includes a buck-boost converter.

11. The power converter circuit of claim 1, wherein:

the power combining converter circuit includes a flyback converter.

12. The power converter circuit of claim 1, wherein:

the power combining converter circuit is configured to combine the regulated voltage output powers of the regulating converters to a single output.

13. The power converter circuit of claim 12, wherein:

the controller is configured to adapt a quantity of capacitors and regulating converters that are operative at a particular time.

14. The power converter circuit of claim 12, wherein:

the controller is configured to adapt a quantity of capacitors and regulating converters that are operative at a particular time based, at least in part, on a line voltage currently being used.

15. The power converter circuit of claim 1, wherein:

the stack of capacitors has three or more stacked capacitors and the set of regulating converters has one converter for each of the three or more stacked capacitors.

16. A machine implemented method of operating a power converter circuit comprising:

rectifying an alternating current (ac) line voltage;

applying the rectified ac line voltage across a stack of capacitors, the stack of capacitors having at least two stacked capacitors;

for each of the capacitor in the stack of capacitors, applying a corresponding voltage to an input of a corresponding regulating converter to convert the voltage to a regulated output signal;

modulating an input current of one or more of the regulating converters in a manner that increases power factor of the power converter circuit; and

combining the regulated output signals of the regulating converters to generate a combined signal and converting the combined signal to a desired direct current (dc) output voltage.

17. The method of claim 16, wherein:

applying the rectified ac line voltage across a stack of capacitors comprises storing energy in the stack of capacitors, wherein the energy stored in the stack of capacitors is utilized to buffer a substantial portion of twice-line-frequency energy processed by the system.

18. The method of claim 16, further comprising:

adapting a select number of capacitors in the stack of capacitors that are active based on a predetermined criterion.

19. The method of claim 16, further comprising:

adapting a select number of capacitors in the stack of capacitors that are active based on a line voltage level currently being used.

20. The method of claim 16, further comprising:

providing electrical isolation between the regulated output signals of the regulating converters and the dc output voltage of the machine implemented method of operating a power converter circuit.

21. The method of claim 16, further comprising:

providing switched capacitive energy transfer to combine the output signals of the regulating converters to provide the dc output voltage of the system.

22. The method of claim 16, further wherein combining the regulated output signals of the regulating converters comprises combining the power delivered to the regulated output signals of the regulating converters to provide the full power to a single combined output of the power converter circuit.

23. A system comprising:

a single phase alternating current (ac) voltage source having a pair of terminals across which on ac signal may be provided; and

a power converter circuit having an input and an output, said power converter circuit comprising;

a line frequency rectifier circuit having a pair of input terminals corresponding to the input of said power converter circuit and a pair of output terminals with a first one of the pair of input terminals coupled a first one of the pair of terminals of said single phase ac voltage source and having a second one of the pair of input terminals coupled to a second one of the pair of terminals of said single phase ac voltage source such that in response to an ac signal provided to the input thereof from said single phase ac voltage source, said line frequency rectifier circuit provides a rectified voltage across the pair of output terminals thereof;

a stacked capacitor circuit provided from a plurality of capacitors, said stacked capacitor circuit having a first terminal coupled to a first one of the pair of output terminals of said line rectifier circuit and having a second terminal coupled to a second one of the pair of output terminals of said line rectifier circuit such that in response to a rectified voltage across the pair of output terminals of said line frequency rectifier circuit, a total voltage across said stacked capacitor circuit is equal to a voltage across the pair of output terminals of said line frequency rectifier circuit;

a set of regulating converters coupled to said the stacked capacitor circuit such that each regulating converter in the set of regulating converters is capable of drawing current from a corresponding one of said plurality of capacitors in said stacked capacitor circuit and generating a regulated voltage output power at an output thereof; and

a power combining converter circuit coupled to said set of regulating converters such that in response to receiving regulated voltage output powers generated by said set of regulating converters, said power combining converter circuit combines the regulated voltage output powers and converts the combined power to a desired direct current (dc) output voltage at the output of said power converter circuit.