Multi-switch power converter

• US 9,935,549 B2
• Filed: 07/08/2016
• Issued: 04/03/2018
• Est. Priority Date: 07/08/2016
• Status: Active Grant

• Current Assignee: Toshiba International Corporation (Toshiba Corporation)
• Original Assignee: Toshiba International Corporation (Toshiba Corporation)
• Inventors: Westmoreland, David Martin
• Primary Examiner(s): Dole, Timothy J
• Assistant Examiner(s): Tiku, Sisay G
• Application Number:
  US15/205,141
• Publication Number:
  US 20180013346A1
• Time in Patent Office: 634 Days
• CPC Class Codes: H02M 1/0054 Transistor switching losses periodically suspending operation of switching converter in low power mode H02M1/0035
• CPC Class Codes: H02M 1/14 Arrangements for reducing ripples from dc input or output
• CPC Class Codes: H02M 1/15 using active elements
• CPC Class Codes: H02M 1/42 Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• 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

In accordance with presently disclosed embodiments, a 5-switch power conversion circuit that improves the power conversion efficiency (PCE) of a DC-DC converter with a double chopper topology is provided. The power conversion circuit adds minimal complexity through an additional switch, while preserving the benefits of a 3-level boost converter topology. The disclosed power conversion circuit uses four switches that are arranged in a 3-level boost converter arrangement, and a fifth switch that is connected in parallel with two of the other switches. The fifth switch helps to reduce the conduction power losses through the DC-DC converter by providing a one-switch ON-state conduction path instead of a two-switch path during part of the DC-DC power conversion cycle.

Claims

1. A power conversion system, comprising:

a 5-switch power conversion circuit comprising;

a voltage supply;

a first inductor coupled to a positive side of the voltage supply and a second inductor coupled to the negative side of the voltage supply;

a DC bus comprising a first capacitor on a positive side of the DC bus and a second capacitor on a negative side of the DC bus;

a first switch transistor, a second switch transistor, a third switch transistor, and a fourth switch transistor each coupled between the at least one inductor and the DC bus in a 3-level DC-DC boost circuit configuration;

a fifth switch transistor disposed between the at least one inductor and the first, second, third, and fourth switch transistors, wherein the fifth switch transistor is coupled in parallel to the second and third switch transistors;

a controller communicatively coupled to the first, second, third, fourth, and fifth switch transistors, wherein the controller is configured to output signals to the first, second, third, fourth, and fifth switch transistors to independently control the positions of the first, second, third, fourth, and fifth switches and wherein the controller is configured to output a signal to the fifth switch transistor to turn the fifth switch transistor to an ON-state when both the second and third switch transistors are in an ON-state such that current will flow through the inductors and the fifth switch transistor instead of through the inductors and the second and third switches so as to reduce conduction losses through the power conversion system due to the current flowing primarily through the fifth switch transistor instead of the second and third switch transistors.

2. The power conversion system of claim 1, wherein the controller is configured to delay turning the fifth switch transistor to the ON-state until after the second and third switch transistors have been in the ON-state for a predetermined amount of time.

3. The power conversion system of claim 1, wherein the controller is configured to output a signal to the fifth switch transistor to turn the fifth switch transistor to an OFF-state a predetermined amount of time before turning either the second switch transistor or the third switch transistor to an OFF-state.

4. The power conversion system of claim 1, wherein the controller is configured to operate the 5-switch power conversion circuit in a DC-DC boost mode.

5. The power conversion system of claim 1, wherein the controller is configured to operate the 5-switch power conversion circuit in a DC-DC step-down mode.

6. The power conversion system of claim 1, wherein the voltage supply comprises a rectified DC input or a DC input supplied by a battery.

7. The power conversion system of claim 1, wherein the first switch transistor is coupled between a first side of the voltage supply and a first side of the first capacitor, the second switch transistor is coupled between the first side of the voltage supply and a second side of the first capacitor, the third switch transistor is coupled between a second side of the voltage supply and a first side of the second capacitor, and the fourth switch transistor is coupled between the second side of the voltage supply and a second side of the second capacitor.

8. A method, comprising:

providing a 5-switch power conversion circuit comprising;

a voltage supply;

at least one inductor coupled to the voltage supply;

a DC bus comprising a first capacitor on a positive side of the DC bus and a second capacitor on a negative side of the DC bus;

a first switch transistor, a second switch transistor, a third switch transistor, and a fourth switch transistor each coupled between the at least one inductor and the DC bus in a 3-level DC-DC boost circuit configuration; and

a fifth switch transistor disposed between the at least one inductor and the first, second, third, and fourth switch transistors, wherein the fifth switch transistor is coupled in parallel to the second and third switch transistors;

operating the 5-switch power conversion circuit in a DC-DC boost mode to convert power input from the voltage supply at a first voltage to power output to the DC bus at a second voltage higher than the first voltage;

controlling an operation of the 5-switch power conversion circuit via control signals sent to selectively actuate the first, second, third, fourth, and fifth switch transistors between an OFF-state and an ON-state; and

actuating the fifth switch transistor from the OFF-state to the ON-state when both the second and third switch transistors are in the ON-state such that current will flow through the inductor and the fifth switch transistor instead of through the inductor and the second and third switches so as to reduce conduction losses through the power conversion system due to the current flowing primarily through the fifth switch transistor instead of the second and third switch transistors.

9. The method of claim 8, further comprising delaying actuation of the fifth switch transistor from the OFF-state to the ON-state until a predetermined amount of time after both the second and third switch transistors are in the ON-state.

10. The method of claim 8, further comprising actuating the fifth switch transistor from the ON-state back to the OFF-state a predetermined amount of time prior to actuating one of the second switch transistor or the third switch transistor from the ON-state to the OFF-state.

11. The method of claim 8, further comprising:

directing current through the voltage supply, the at least one inductor, and the fifth switch transistor to store energy in the at least one inductor;

directing current through the at least one inductor, a free-wheeling diode of the first switch transistor, the first capacitor, and the third switch transistor to output stored energy from the inductor to the positive side of the DC bus; and

directing current through the at least one inductor, the second switch transistor, the second capacitor, and a free-wheeling diode of the fourth switch transistor to output stored energy from the inductor to the negative side of the DC bus.

12. The method of claim 8, further comprising operating the 5-switch power conversion circuit in a DC-DC step-down mode to draw power from the DC bus to recharge the voltage supply.

13. The method of claim 12, further comprising drawing power from both sides of the DC bus to recharge the voltage supply when a battery voltage of the voltage supply is greater than a DC bus voltage of the DC bus divided by two.

14. The method of claim 12, further comprising drawing power from the positive side or the negative side to recharge the voltage supply when a battery voltage of the voltage supply is less than a DC bus voltage of the DC bus divided by two.

15. The method of claim 12, further comprising:

directing power from one or both sides of the DC bus via current flowing through the at least one inductor, one or both capacitors, and two of the switch transistors to store energy in the at least one inductor; and

directing current through the at least one inductor, the voltage supply, and a free-wheeling diode of the fifth switch transistor to output the stored energy from the at least one inductor to the voltage supply.

16. The method of claim 12, further comprising controlling the operation of the 5-switch power conversion circuit in the DC-DC step-down mode by actuating one or both of the first switch transistor and the fourth switch transistor between an OFF-state and an ON-state.