Power conversion device and in-vehicle power supply device equipped with same

• US 9,787,190 B2
• Filed: 02/06/2012
• Issued: 10/10/2017
• Est. Priority Date: 04/18/2011
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Electric Corporation
• Inventors: Takeshima, Yoshihiro, Yamada, Masaki, Yano, Takuto
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): Demisse, Afework
• Application Number:
  US14/111,314
• Publication Number:
  US 20140028092A1
• Time in Patent Office: 2,073 Days
• Field of Search: 363 17
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: H02M 1/0032 Control circuits allowing low power mode operation, e.g. in standby mode
• CPC Class Codes: H02M 1/0058 by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826
• CPC Class Codes: H02M 1/38 Means for preventing simultaneous conduction of switches
• CPC Class Codes: H02M 3/33507 with automatic control of the output voltage or current, e.g. flyback converters H02M3/33561, H02M3/33569 take precedence
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• 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

In a DC/DC converter that performs zero-voltage switching, capacitors are connected respectively in parallel to first and second MOSFETs that are included in an inverter unit in the primary-side of a transformer, and an inductor is connected to an AC output line. In a range of a current being more than a predetermined value, a control circuit controls the inverter unit using a PWM control with a fixed dead time, and in a light load range where the current is equal to or less than the predetermined value, the control unit changes the control to a PFM control and decreases a frequency so that the dead time becomes longer as the current decreases, to thereby keep a duty ratio without change.

Claims

1. A power conversion device comprising:

a DC/DC converter that includes an inverter unit having two serial semiconductor switching elements for converting a DC power to an AC power, a rectifier circuit for rectifying an AC output from the inverter unit, and a smoothing circuit for smoothing a rectified voltage to output a DC power to a load; and

a control circuit for controlling the inverter unit,

wherein the inverter unit includes capacitors connected respectively in parallel to the semiconductor switching elements, and an inductor, connected to a line of the AC output, which is made variable in its inductance according to a circuit current flowing through the DC/DC converter, so that the inductance decreases as the circuit current increases,

the control circuit changes a dead time, which is a time period where both of said two serial semiconductor switching elements are made OFF, according to the circuit current, so as to cause the respective semiconductor switching elements to perform zero-voltage switching, and

at least in the range of the circuit current being equal to or less than a predetermined value, the control circuit controls the inverter unit using a PFM control.

2. The power conversion device of claim 1, wherein the control circuit controls the inverter unit using a PWM control in the range of the circuit current being more than the predetermined value, and then changes this control to the PFM control when the circuit current becomes the predetermined value or less.

3. The power conversion device of claim 1, wherein the control unit increases the dead time when the circuit current decreases.

4. The power conversion device of claim 1, further comprising a current detector that detects the circuit current flowing through the DC/DC converter.

5. The power conversion device of claim 1, further comprising, between DC bus lines of the inverter unit, two serial voltage-dividing capacitors for dividing an input DC voltage, so that the inverter unit is configured as a half-bridge inverter.

6. The power conversion device of claim 1, further comprising a transformer connected to the AC side of the inverter unit, wherein a primary winding of the transformer, the inductor and the line of the AC output are connected serially, and a secondary winding of the transformer is connected to the rectifier circuit.

7. The power conversion device of claim 1, wherein the rectifier circuit includes a semiconductor switching element, and the control circuit controls switching of the semiconductor switching element in the rectifier circuit, in synchronization with said two serial semiconductor switching elements in the inverter unit.

8. The power conversion device of claim 7, wherein the semiconductor switching element in the rectifier circuit is formed of a wide bandgap semiconductor that is wider in bandgap than silicon.

9. The power conversion device of claim 1, wherein the semiconductor switching elements in the inverter unit are formed of a wide bandgap semiconductor that is wider in bandgap than silicon.

10. A power conversion device comprising:

a DC/DC converter that includes an inverter unit having two serial semiconductor switching elements, for converting a DC power to an AC power, a rectifier circuit for rectifying an AC output from the inverter unit, and a smoothing circuit for smoothing a rectified voltage to output a DC power to a load; and

a control circuit for controlling the inverter unit,

wherein the inverter unit includes capacitors connected respectively in parallel to the semiconductor switching elements, and an inductor connected to a line of the AC output,

the control circuit changes a dead time, which is a time period where both of said two serial semiconductor switching elements are made OFF, according to a circuit current flowing through the DC/DC converter, so as to cause the respective semiconductor switching elements to perform zero-voltage switching,

at least in the range of the circuit current being equal to or less than a predetermined value, the control circuit controls the inverter unit using a PFM control, and

a voltage between both ends of one of said two serial semiconductor switching elements is detected, and the control circuit adjusts switching of said two serial semiconductor switching elements according to the voltage detected.

11. The power conversion device of claim 10, wherein the control circuit controls the inverter unit using a PWM control in the range of the circuit current being more than the predetermined value, and then changes this control to the PFM control when the circuit current becomes the predetermined value or less.

12. The power conversion device of claim 10, wherein the control unit increases the dead time when the circuit current decreases.

13. The power conversion device of claim 10, further comprising a current detector that detects the circuit current flowing through the DC/DC converter.

14. The power conversion device of claim 10, further comprising, between DC bus lines of the inverter unit, two serial voltage-dividing capacitors for dividing an input DC voltage, so that the inverter unit is configured as a half-bridge inverter.

15. The power conversion device of claim 10, further comprising a transformer connected to the AC side of the inverter unit, wherein a primary winding of the transformer, the inductor and the line of the AC output are connected serially, and a secondary winding of the transformer is connected to the rectifier circuit.

16. The power conversion device of claim 10, wherein the rectifier circuit includes a semiconductor switching element, and the control circuit controls switching of the semiconductor switching element in the rectifier circuit, in synchronization with said two serial semiconductor switching elements in the inverter unit.

17. The power conversion device of claim 16, wherein the semiconductor switching element in the rectifier circuit is formed of a wide bandgap semiconductor that is wider in bandgap than silicon.

18. The power conversion device of claim 10, wherein the semiconductor switching elements in the inverter unit are formed of a wide bandgap semiconductor that is wider in bandgap than silicon.

19. An in-vehicle power supply device comprising:

a power conversion device; and

a battery for driving a motor for running,

said power conversion device including

a DC/DC converter that includes an inverter unit having two serial semiconductor switching elements for converting a DC power to an AC power, a rectifier circuit for rectifying an AC output from the inverter unit, and a smoothing circuit for smoothing a rectified voltage to output a DC power to a load, and

a control circuit for controlling the inverter unit,

wherein the inverter unit includes capacitors connected respectively in parallel to the semiconductor switching elements, and an inductor, connected to a line of the AC output, which is made variable in its inductance according to a circuit current flowing through the DC/DC converter, so that the inductance decreases as the circuit current increases, and the DC power is input to the inverter unit from the battery,

the control circuit changes a dead time, which is a time period where both of said two serial semiconductor switching elements are made OFF, according to the circuit current, so as to cause the respective semiconductor switching elements to perform zero-voltage switching, and

in the range of the circuit current being equal to or less than a predetermined value, the control circuit controls the inverter unit using a PFM control.

20. An in-vehicle power supply device comprising:

a power conversion device; and

a battery for driving a motor for running,

said power conversion device including

a DC/DC converter that includes an inverter unit having two serial semiconductor switching elements for converting a DC power to an AC power, a rectifier circuit for rectifying an AC output from the inverter unit, and a smoothing circuit for smoothing a rectified voltage to output a DC power to a load, and

a control circuit for controlling the inverter unit,

wherein the inverter unit includes capacitors connected respectively in parallel to the semiconductor switching elements, and an inductor connected to a line of the AC output,

the DC power is input to the inverter unit from the battery,

the control circuit changes a dead time, which is a time period where both of said two serial semiconductor switching elements are made OFF, according to a circuit current flowing through the DC/DC converter, so as to cause the respective semiconductor switching elements to perform zero-voltage switching,

in the range of the circuit current being equal to or less than a predetermined value, the control circuit controls the inverter unit using a PFM control, and

a voltage between both ends of one of said two serial semiconductor switching elements is detected, and the control circuit adjusts switching of said two serial semiconductor switching elements according to the voltage detected.