Bi-directional DC-DC power converter for a vehicle system

• US 9,809,119 B2
• Filed: 01/13/2015
• Issued: 11/07/2017
• Est. Priority Date: 01/13/2015
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: She, Xu, King, Robert Dean, Huh, Kum-Kang
• Primary Examiner(s): Hiltunen, Thomas J
• Application Number:
  US14/595,706
• Publication Number:
  US 20160200202A1
• Time in Patent Office: 1,029 Days
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 50/50 using propulsion power supplied by batteries or fuel cells
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: H02M 1/0093 wherein the output is created by adding a regulated voltage to or subtracting it from an unregulated input
• CPC Class Codes: H02M 3/335 using semiconductor devices only
• CPC Class Codes: H02M 3/33584 Bidirectional converters
• 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 90/14 Plug-in electric vehicles

Abstract

A bi-directional DC-DC converter assembly that processes and transfers differential power in a variable manner is disclosed. The converter assembly is coupled to an energy storage device and DC link, with the converter assembly including a first converter section coupled to the energy storage device and a second converter section coupled to the DC link and to the energy storage device. The converter assembly processes a first portion of the DC power output of the energy storage device and provides an unprocessed second portion of the DC power output of the energy storage device to the second converter section when providing power to the load, and processes a first portion of a regenerative power from the load and provides an unprocessed second portion of the regenerative power from the load to the first converter section when providing regenerative power to the energy storage device.

Claims

1. A vehicle system comprising:

a direct current (DC) link;

an energy storage device; and

a bi-directional DC-DC converter assembly coupled to each of between the energy storage device and the DC link, the bi-directional DC-DC converter assembly comprising;

a first converter section coupled to the energy storage device; and

a second converter section coupled to the DC link and the energy storage device;

wherein the bi-directional DC-DC converter assembly is configured to;

process a first portion of power received from the energy storage device, the processed first portion of power determined by a voltage differential between the energy storage device and the DC link; and

provide the processed first portion of power and an unprocessed second portion of power to the second converter section, the unprocessed second portion of power also determined by the voltage differential.

2. The vehicle system of claim 1 wherein the first converter section and the second converter section each comprise a positive terminal and a negative terminal, the negative terminal of the second converter section being connected in series with the positive terminal of the first converter section.

3. The vehicle system of claim 1 wherein the bi-directional DC-DC converter assembly comprises at least one transformer, with the first converter section comprising a primary winding of the transformer and the second converter section comprising a secondary winding of the transformer.

4. The vehicle system of claim 3 wherein the primary winding receives the first processed portion of power and induces a voltage across the secondary winding that is combined with the second unprocessed portion of power to generate a combined power output from the bi-directional DC-DC converter assembly.

5. The vehicle system of claim 3 wherein the first converter section and the second converter section each comprise a switching network to control current through the primary and secondary windings of the bi-directional DC-DC converter assembly.

6. The vehicle system of claim 5 wherein the switching networks each comprise a half-bridge circuit or a full-bridge circuit.

7. The vehicle system of claim 3 wherein the first converter section and the second converter section each comprise a voltage fed or current fed converter.

8. The vehicle system of claim 1 further comprising a controller configured to control operation of the first converter section and the second converter section based on the voltage differential.

9. The vehicle system of claim 8 wherein the controller is programmed to increase a value of the processed first portion of power and decrease a value of the unprocessed second portion of power as the voltage differential increases.

10. The vehicle system of claim 1 further comprising a second energy storage device coupled between the DC link and the bi-directional DC-DC converter assembly.

11. A vehicle system comprising:

a direct current (DC) link;

an energy storage device;

a bi-directional DC-to-DC partial power converter coupled between the energy storage device and the DC link; and

a controller configured to selectively operate the bi-directional DC-to-DC partial power converter in boost mode to boost a voltage from the energy storage device to the DC link and a buck mode to buck a voltage from the DC link to the energy storage device, the controller programmed to;

determine a value of a processed portion of power received by the bi-directional DC-to-DC partial power converter; and

determine a value of an unprocessed portion of power received by the bi-directional DC-to-DC partial power converter;

wherein the values of the processed and unprocessed portions of power are based on a voltage differential between the energy storage device and the DC link.

12. The vehicle system of claim 11 wherein the bi-directional DC-to-DC partial power converter comprises:

a first converter section coupled to the energy storage device; and

a second converter section coupled to the DC link;

wherein the unprocessed portion of power bypasses one of the first and second converter sections.

13. The vehicle system of claim 12 wherein the bi-directional DC-to-DC partial power converter comprises at least one transformer, with the first converter section comprising a primary winding of the transformer and the second converter section comprising a secondary winding of the transformer.

14. The vehicle system of claim 13 wherein the first converter section and the second converter section each comprise a switching network to control current through the primary and secondary windings.

15. The vehicle system of claim 11 further comprising a load coupled to the DC link.

16. A method of transferring power in a vehicle system that includes an energy storage device, a direct current (DC) link, a load, and a bi-directional DC-DC converter assembly, the method comprising:

operating the bi-directional DC-DC converter assembly in a boost mode to boost a DC voltage from an output of the energy storage device to the DC link or in a buck mode to buck voltage from the DC link to the energy storage device;

wherein operating the bi-directional DC-DC converter assembly in the boost mode or the buck mode comprises;

determining a voltage differential between the energy storage device and the DC link;

determining a first portion of power received by the bi-directional DC-DC converter assembly to be processed, so as to boost or buck the received power;

determining a second portion of power received by the bi-directional DC-DC converter assembly to remain unprocessed;

causing the bi-directional DC-DC converter assembly to process the first portion of the received power and leave the second portion of the received power unprocessed; and

collectively outputting the processed first portion and unprocessed second portion from the bi-directional DC-DC converter assembly.

17. The method of claim 16 wherein causing the bi-directional DC-DC converter assembly to leave the second portion of the received power unprocessed comprises causing the second portion of power received by the bi-directional DC-DC converter assembly to bypass one of a first converter section and a second converter section of the bi-directional DC-DC converter assembly.

18. A vehicle system comprising:

a direct current (DC) link;

an energy storage device; and

a bi-directional DC-DC converter coupled between the energy storage device and the DC link, the bi-directional DC-DC converter comprising;

a first converter section coupled to the energy storage device; and

a second converter section coupled to the DC link and the energy storage device;

wherein the bi-directional DC-DC converter assembly is configured to;

process a first portion of regenerative power received from the DC link, the processed first portion of regenerative power determined by a voltage differential between the energy storage device and the DC link; and

provide the processed first portion of regenerative power and an unprocessed second portion of regenerative power to the first converter section, the unprocessed second portion of regenerative power also determined by the voltage differential.

19. The vehicle system of claim 18 wherein the bi-directional DC-DC converter assembly comprises at least one transformer, with the first converter section comprising a primary winding of the transformer and the second converter section comprising a secondary winding of the transformer.

20. The vehicle system of claim 19 wherein the secondary winding receives the first processed portion of regenerative power and induces a voltage across the primary winding that is combined with the second unprocessed portion of regenerative power to generate a combined power output from the bi-directional DC-DC converter.

21. The vehicle system of claim 18 further comprising a controller configured to control operation of the first converter section and the second converter section based on the voltage differential.

22. The vehicle system of claim 21 wherein the controller is programmed to increase a value of the first processed portion of regenerative power and decrease a value of the second unprocessed portion of regenerative power as the voltage differential increases.