DC-DC power conversion and balancing circuit

• US 9,866,132 B2
• Filed: 07/31/2015
• Issued: 01/09/2018
• Est. Priority Date: 07/31/2015
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Ishigaki, Masanori
• Primary Examiner(s): AHMED, YUSEF A
• Application Number:
  US14/815,754
• Publication Number:
  US 20170033700A1
• Time in Patent Office: 893 Days
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• CPC Class Codes: H02M 3/33584 Bidirectional converters
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers

Abstract

A system includes DC-DC power conversion circuitry having a first switch and a second switch on either side of a first transformer with a first pair of capacitors and a second pair of capacitors cross-connected across the transformer. Balancing circuitry includes a primary side of a second transformer connected between the first pair of capacitors and the second pair of capacitors of the DC-DC power conversion circuitry. Control circuitry is configured to determine a direction of power transfer through the DC-DC power conversion circuitry, align a primary side and a secondary side of the DC-DC power conversion circuitry based on the determined direction of power transfer, align the balancing circuitry to perform balanced or unbalanced operations, and control switching of the first switch and the second switch.

Claims

1. A system comprising:

DC-DC power conversion circuitry including a first switch and a second switch on either side of a first transformer with a first pair of capacitors and a second pair of capacitors cross-connected across the first transformer;

balancing circuitry including a primary side of a second transformer connected between the first pair of capacitors and the second pair of capacitors of the DC-DC power conversion circuitry; and

control circuitry configured to;

determine a direction of power transfer through the DC-DC power conversion circuitry,

align a primary side and a secondary side of the DC-DC power conversion circuitry based on the determined direction of power transfer,

align the balancing circuitry to perform balanced or unbalanced operations, and

control switching of the first switch and the second switch.

2. The system of claim 1, wherein the DC-DC power conversion circuitry is configured to perform bi-directional power transfer.

3. The system of claim 2, wherein the control circuitry is further configured to determine the direction of power transfer by selecting the first switch or the second switch to cycle on and off.

4. The system of claim 1, wherein a secondary side of the second transformer includes one or more taps connected to one or more source cells.

5. The system of claim 4, wherein the one or more source cells are connected to the one or more taps of the second transformer via a diode.

6. The system of claim 4, wherein the one or more source cells are battery cells.

7. The system of claim 4, wherein the balancing circuitry is configured to balance states of charge (SOCs) of the one or more source cells having unequal voltages.

8. The system of claim 1, wherein the second transformer is activated by an alternating voltage produced between the first pair of capacitors and the second pair of capacitors as power is transferred between the primary side and the secondary side of the DC-DC power conversion circuitry.

9. The system of claim 1, wherein the balancing circuitry includes a third switch connecting the balancing circuitry to the DC-DC power conversion circuitry.

10. The system of claim 9, wherein the control circuitry is further configured to align the balancing circuitry for balanced operations by issuing a control signal to close the third switch.

11. The system of claim 9, wherein the control circuitry is further configured to align the balancing circuitry for unbalanced operations by issuing a control signal to open the third switch.

12. The system of claim 1, wherein the control circuitry is further configured to align the balancing circuitry for balanced operations when a difference in voltage between one or more source cells is greater than a predetermined threshold.

13. The system of claim 1, wherein the control circuitry is further configured to align the balancing circuitry for balanced operations when a voltage of one or more source cells is at least one of less than a lower threshold or greater than an upper threshold.

14. The system of claim 1, wherein the balancing circuitry is further configured to perform cell balancing operations during charging and discharging of one or more source cells.

15. The system of claim 1, wherein the second transformer of the balancing circuitry has a higher excitation impedance than a total excitation impedance of the first transformer, the first capacitor pair, and the second capacitor pair of the DC-DC power conversion circuitry.

16. The system of claim 1, wherein the DC-DC power conversion circuitry has higher rates of energy transfer than the balancing circuitry.

17. The system of claim 1, wherein the balancing circuitry is configured to provide no interference to operations of the DC-DC power conversion circuitry.

18. A method comprising:

determining a direction of power transfer through DC-DC power conversion circuitry including a first switch and a second switch on either side of a first transformer with a first pair of capacitors and a second pair of capacitors cross-connected across the first transformer;

aligning a primary side and a secondary side of the DC-DC power conversion circuitry based on the determined direction of power transfer;

aligning balancing circuitry including a primary side of a second transformer connected between the first pair of capacitors and the second pair of capacitors of the DC-DC power conversion circuitry to perform balanced or unbalanced operations; and

controlling switching of the first switch and the second switch.

19. A non-transitory computer-readable storage medium including executable instructions, which when executed by circuitry, causes the circuitry to perform the method according to claim 18.

20. A system comprising:

circuitry configured to

determine a direction of power transfer through DC-DC power conversion circuitry including a first switch and a second switch on either side of a first transformer with a first pair of capacitors and a second pair of capacitors cross-connected across the first transformer,

align a primary side and a secondary side of the DC-DC power conversion circuitry based on the determined direction of power transfer,

align balancing circuitry including a primary side of a second transformer connected between the first pair of capacitors and the second pair of capacitors of the DC-DC power conversion circuitry to perform balanced or unbalanced operations, and

control switching of the first switch and the second switch.