Bridgeless single-stage AC/DC converter

• US 10,879,813 B2
• Filed: 09/19/2019
• Issued: 12/29/2020
• Est. Priority Date: 09/21/2018
• Status: Active Grant

• Current Assignee: Delta-Q Technologies Corp. (ZAPI S.p.A.)
• Original Assignee: Delta-Q Technologies Corp. (ZAPI S.p.A.)
• Inventors: Askarianabyaneh, Iman, Dohmeier, Nicholas Adam, Pahlevaninezhad, Majid, Botting, Christopher Jon
• Primary Examiner(s): Laxton, Gary L
• Application Number:
  US16/576,606
• Publication Number:
  US 20200099311A1
• Time in Patent Office: 467 Days
• CPC Class Codes: H02M 1/0035 using burst mode control
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 1/123 Suppression of common mode voltage or current
• CPC Class Codes: H02M 1/4241 using a resonant converter
• CPC Class Codes: H02M 1/4258 using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage H02M1/4241 takes precedence
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• 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: H02M 7/217 using semiconductor devices only
• CPC Class Codes: H02M 7/4818 with means for adaptation of resonance frequency, e.g. by modification of capacitance or inductance of resonance circuits
• 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 single-stage AC/DC converter includes a boost PFC AC/DC converter and a half-bridge split-capacitor DC/DC converter. The boost PFC AC/DC converter includes a boost inductor, and the half-bridge split-capacitor DC/DC converter includes an inductor in series with a primary winding of a transformer. A method of operation of a single-stage AC/DC converter that includes a boost PFC AC/DC converter and a half-bridge split-capacitor DC/DC converter includes modulating a switching frequency of at least one switch. The method may further include maintaining a constant duty cycle, for example a duty cycle of 0.5. An implementation of the boost inductor in a boost PFC AC/DC converter of a single-stage AC/DC converter includes a variable boost inductor, such as two inductors of approximately equal inductance, and a boost inductor switching circuit, such as two single-pole, double-throw relays.

Claims

1. An apparatus comprising:

a transformer comprising a primary winding and a secondary winding, the primary winding comprising a first end and a second end of the primary winding, and the secondary winding comprising a first end and a second end of the secondary winding;

a first AC voltage source input connectable to a first AC input line;

a second AC voltage source input connectable to a second AC input line;

a first inductor connected between the first AC voltage source input and a central node;

a first switch connected between the central node and a first rail node, the first rail node connected to the second end of the primary winding;

a first diode oriented to pass current from the first rail node to the central node;

a second switch connected between the central node and a second rail node;

a second diode oriented to pass current from the central node to the second rail node;

a first input rectifier connected between the first rail node and the second AC voltage source input and oriented to pass current from the first rail node to the second AC voltage source input;

a second input rectifier connected between the second rail node and the second AC voltage source input and oriented to pass current from the second AC voltage source input to the second rail node;

a second inductor connected between the central node and the first end of the primary winding of the transformer;

a first capacitor connected between the second rail node and the second end of the primary winding of the transformer; and

an output rectifier circuit connected between the secondary winding of the transformer and a load, wherein, in operation, the apparatus delivers a DC current to the load via the output rectifier circuit.

2. The apparatus of claim 1, further comprising a second capacitor connected between the first rail node and the second end of the primary winding of the transformer.

3. The apparatus of claim 1 wherein the output rectifier circuit comprises:

a first output rectifier connected between the first end of the secondary winding of the transformer and a third rail node, and oriented to pass current from the first end of the secondary winding of the transformer to the third rail node; and

a second output rectifier connected between the second end of the secondary winding of the transformer and the third rail node, and oriented to pass current from the second end of the secondary winding of the transformer to the third rail node, wherein, in operation, the apparatus delivers the DC current to the load via the third rail node.

4. The apparatus of claim 3 wherein at least one of the first input rectifier, the second input rectifier, the first output rectifier, and the second output rectifier comprises one of a diode or a controllable switch.

5. The apparatus of claim 3 wherein the transformer is a center-tapped transformer.

6. The apparatus of claim 1 wherein the first diode is a body diode of the first switch, and the second diode is a body diode of the second switch.

7. The apparatus of claim 1 wherein the first inductor comprises a variable inductor having a selectively variable inductance.

8. The apparatus of claim 7 wherein the variable inductor comprises two inductors, and the apparatus further comprises:

a first inductor switching circuit operatively coupled to the two inductors of the variable inductor, the first inductor switching circuit which in operation selectively couples the two inductors in a parallel configuration or a series configuration to provide two different levels of inductance for the variable inductor.

9. The apparatus of claim 1 wherein the second inductor comprises a leakage inductance of the primary winding of the transformer.

10. The apparatus of claim 1 wherein the first switch and the second switch comprise MOSFETs.

11. The apparatus of claim 1, further comprising:

a control system operatively coupled to the first switch and the second switch, the control system which in operation selectively controls the first switch and the second switch by varying at least one of a respective switching frequency or a respective duty cycle of the first switch and the second switch.

12. The apparatus of claim 11 wherein the control system, in operation, selectively controls the first switch and the second switch to provide zero voltage switching (ZVS) operation.

13. The apparatus of claim 11 wherein the control system in operation receives at least one feedback signal indicative of an output of the apparatus, and selectively controls the first switch and the second switch based at least in part on the at least one received feedback signal.

14. The apparatus of claim 11 wherein the control system, in operation, selectively controls the first switch and the second switch to cause the first inductor to operate in a Discontinuous Conduction Mode (DCM).

15. The apparatus of claim 1 wherein the first capacitor is a storage capacitor that forms a primary side DC bus between the first rail node and the second rail node.

16. The apparatus of claim 2 wherein the first capacitor and the second capacitor are storage capacitors that form a primary side DC bus between the first rail node and the second rail node.

17. The apparatus of claim 1 wherein, in operation, the first switch and the second switch maintain a constant duty cycle of approximately 0.5 (50%), and the apparatus varies the DC current by modulating a switching frequency of the first switch and the second switch.

18. The apparatus of claim 7 wherein, in operation, an inductance of the selectively variable inductance is based at least in part on a voltage of an AC input line.

19. The apparatus of claim 11 wherein, in operation, the control system selectively controls the first switch and the second switch to maintain a constant duty cycle of approximately 0.5 (50%) for each of the first switch and the second switch, and selectively controls the first switch and the second switch to vary the DC current by modulating a switching frequency of the first switch and the second switch.

20. A method of controlling a single-stage AC/DC converter, the AC/DC converter comprising a boost PFC AC/DC converter and a half-bridge DC/DC converter, the boost PFC AC/DC converter and the half-bridge DC/DC converter sharing a pair of switches, wherein a boost inductor of the boost PFC AC/DC converter has a selectively variable inductance, the method comprising:

modulating a respective switching frequency of each of the pair of switches; and

selectively varying the inductance of the boost inductor based at least in part on a voltage of an AC input line.

21. A method of controlling a single-stage AC/DC converter, the AC/DC converter comprising a boost PFC AC/DC converter and a half-bridge DC/DC converter, the boost PFC AC/DC converter and the half-bridge DC/DC converter sharing a pair of switches, wherein a boost inductor of the boost PFC AC/DC converter comprises two inductors, and the boost PFC AC/DC converter comprises a boost inductor switching circuit operatively coupled to the two inductors, the method comprising:

modulating a respective switching frequency of each of the pair of switches; and

controlling the boost inductor switching circuit to cause the boost inductor switching circuit to couple the two inductors in a parallel configuration or a series configuration based at least in part on a voltage of an AC input line connected to the AC/DC converter.