Power system method and apparatus

• US 20060152085A1
• Filed: 10/20/2005
• Published: 07/13/2006
• Est. Priority Date: 10/20/2004
• Status: Abandoned Application

• Current Assignee: Siemens VDO Automotive Corporation (Siemens AG)
• Original Assignee: Siemens VDO Automotive Corporation (Siemens AG)
• Inventors: Zhu, Lizhi, Flett, Fred, Ahmed, Sayeed, Patwardhan, Ajay V., Davis, Roy I.
• Application Number:
  US11/255,162
• Publication Number:
  US 20060152085A1
• Time in Patent Office: Days
• US Class Current: 307/75
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 9/30 fed from different kinds of power-supply lines
• CPC Class Codes: H01L 2224/49111 the connectors connecting two common bonding areas, e.g. Litz or braid wires
• CPC Class Codes: H01L 2224/49113 the connectors connecting different bonding areas on the semiconductor or solid-state body to a common bonding area outside the body, e.g. converging wires
• CPC Class Codes: H01L 2224/49175 Parallel arrangements
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/13055 Insulated gate bipolar transistor [IGBT]
• CPC Class Codes: H01L 2924/13091 Metal-Oxide-Semiconductor Field-Effect Transistor [MOSFET]
• CPC Class Codes: H01L 2924/19107 off-chip wires
• CPC Class Codes: H01M 8/04537 Electric variables
• CPC Class Codes: H01M 8/04858 Electric variables
• CPC Class Codes: H01M 8/249 comprising two or more groupings of fuel cells, e.g. modular assemblies
• CPC Class Codes: H02M 1/0074 Plural converter units whose inputs are connected in series
• CPC Class Codes: H02M 1/0085 Partially controlled bridges
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/487 Neutral point clamped inverters
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility

Abstract

Power converter system topologies comprise a first DC/DC converter to pull a positive rail of a high voltage bus up, while a second DC/DC converter pushes a negative rail of the high voltage bus down. One or both the DC/DC converters may be bi-directional. Such topologies are suitable for use with separate primary power sources, and/or auxiliary power sources. Such topologies may include a DC/AC converter, which may be bi-directional. Such topologies may include one or more auxiliary DC/DC converters, which may be bi-directional. Multiple substrates, including at least one stacked above another may enhance packaging.

Claims

1. A power system comprising:

a high side DC power bus comprising a first voltage rail and a second voltage rail;

a first low side DC power bus;

a second low side DC power bus;

first means for boosting a potential on the first voltage rail of the high side DC power bus above a high potential of the first low side DC power bus; and

second means for boosting a potential on the second voltage rail of the high side DC power bus below a low potential of the second low side DC power bus.

2. The power system of claim 1 wherein the first means for boosting a potential on the first voltage rail of the high side DC power bus above a high potential of the first low side DC power bus comprises a first DC/DC power converter circuit, and wherein the second means for boosting a potential on the second voltage rail of the high side DC power bus below a low potential of the second low side DC power bus comprises a second DC/DC power converter circuit, an output of each of the first and the second DC/DC power converter circuits electrically coupled in series with one another across the high side DC power bus during at least one time.

3. The power system of claim 2 wherein the first DC/DC power converter circuit is a DC/DC boost power converter circuit.

4. The power system of claim 2 wherein the first DC/DC power converter circuit is a DC/DC buck-boost power converter circuit.

5. The power system of claim 2 wherein the first DC/DC power converter circuit is electrically coupled between an upper voltage rail of the first low side DC power bus and an intermediate node, and wherein the second DC/DC power converter circuit is electrically coupled between a lower voltage rail of the second low side DC power bus and the intermediate node, wherein the intermediate node electrically couples a lower voltage rail of the first low side DC power bus and an upper voltage rail of the second low side DC power bus.

6. The power system of claim 2 wherein the first DC/DC power converter circuit comprises at least a first inductor electrically coupled in series to an upper voltage rail of the first low side DC power bus, and wherein the second DC/DC power converter circuit comprises at least a second inductor electrically coupled in series to a lower voltage rail of the second low side DC power bus, and further comprising:

at least a first capacitor electrically coupled across an output of the first DC/DC power converter circuit; and

at least a second capacitor electrically coupled across an output of the second DC/DC power converter circuit.

7. The power system of claim 6, wherein the first DC/DC power converter circuit comprises at least a first diode electrically coupled in series to an output of the first DC/DC power converter circuit;

and wherein the second DC/DC power converter circuit comprises at least a second diode electrically coupled in series to an output of the second DC/DC power converter circuit.

8. The power system of claim 7 wherein the first and the second diodes are each silicon carbide diodes.

9. The power system of claim 2, further comprising:

an auxiliary energy storage device; and

an auxiliary buck-boost power converter electrically coupling the auxiliary energy storage device to the high side DC power bus.

10. The power system of claim 9, further comprising:

a DC/AC power converter electrically coupled in series between the output of the first DC/DC power converter circuit and the output of the second DC/DC power converter circuit, wherein at least one pair of switches of the auxiliary buck-boost power converter are electrically coupled in parallel with at least one pair of switches of the DC/AC power converter.

11. The power system of claim 9, further comprising:

a DC/AC power converter electrically coupled in series between the output of the first DC/DC power converter circuit and the output of the second DC/DC power converter circuit, wherein at least one pair of switches of the auxiliary buck-boost power converter are electrically coupled in series with at least one pair of switches of the DC/AC power converter.

12. The power system of claim 2 wherein the first DC/DC power converter circuit is electrically coupled across an upper and a lower voltage rail of the first low side DC power bus and the second DC/DC power converter circuit is electrically coupled across an upper and a lower voltage rail of the second low side DC power bus, wherein the upper voltage rails of the first and the second low side DC power buses are electrically commonly coupled, and wherein the lower voltage rails of the first and the second low side DC power buses are electrically commonly coupled.

13. The power system of claim 12 wherein the first DC/DC power converter circuit comprises at least a first inductor electrically coupled in series to the upper voltage rail of the first low side DC power bus, and wherein the second DC/DC power converter circuit comprises at least a second inductor electrically coupled in series to the upper voltage rail of the second low side DC power bus, and further comprising:

at least a first capacitor electrically coupled in parallel across the first and the second DC/DC power converter circuits.

14. The power system of claim 13, wherein the first DC/DC power converter circuit comprises at least a first diode electrically coupled in series to an output of the first DC/DC power converter circuit;

and wherein the second DC/DC power converter circuit comprises at least a second diode electrically coupled in series to an output of the second DC/DC power converter circuit.

15. The power system of claim 14 wherein the first and the second diodes are each silicon carbide diodes.

16. The power system of claim 12, further comprising:

an auxiliary power source; and

an auxiliary power converter electrically coupling the auxiliary power source to the high side DC power bus.

17. The power system of claim 16 wherein the auxiliary power source is an auxiliary power storage device and wherein the auxiliary power converter is an auxiliary buck-boost power converter.

18. The power system of claim 17 wherein the auxiliary buck-boost power converter comprises an inductor and at least one switch, the at least one switch electrically coupled in series with a switch of the second DC/DC power converter circuit.

19. The power system of claim 17 wherein the auxiliary buck-boost power converter comprises an inductor electrically coupled in parallel with a number of inductors of the second DC/DC power converter circuit.

20. The power system of claim 2 wherein at least one of the first and the second DC/DC power converter circuits is an interleaved power converter circuit.

21. The power system of claim 1, further comprising:

a first fuel cell system comprising a first fuel cell stack electrically coupled to supply a voltage across the first low side DC power bus; and

a second fuel cell system comprising a second fuel cell stack electrically coupled to supply a voltage across the second low side DC power bus.

22. The power system of claim 1, further comprising:

a first fuel cell system comprising a first fuel cell stack electrically coupled to supply a voltage across the first low side DC power bus and a second fuel cell stack electrically coupled to supply a voltage across the second low side DC power bus.

23. The power system of claim 1, further comprising:

a first fuel cell system comprising a fuel cell stack having a first portion and a second portion, the first portion of the fuel cell stack electrically coupled to supply a voltage across the first low side DC power bus and the second portion of the fuel cell stack electrically coupled to supply a voltage across the second low side DC power bus.

24. The power system of claim 23, wherein the fuel cell system comprises:

at least one center-tapped fuel cell stack divided into the first portion and the second portion by a center tap.

25. A power system, comprising:

a high side DC power bus;

a first low side DC power bus;

a second low side DC power bus;

a first DC/DC power converter electrically coupled to the first low side DC power bus and operable to transform power between the first low side DC power bus and the high side DC power bus; and

a second DC/DC power converter electrically coupled to the second low side DC power bus and operable to transform power between the first low side DC power bus and the high side DC power bus, wherein the first and the second DC/DC power converters are electrically coupled in series with one another across the high side DC power bus during at least one time.

26. The power system of claim 25 wherein one of the first or the second DC/DC power converters is a boost DC/DC power converter circuit, and the other one of the first or the second DC/DC power converters is a buck-boost DC/DC power converter circuit.

27. The power system of claim 25 wherein the first and the second DC/DC power converters are respective boost DC/DC power converter circuits operable to boost respective voltages across the first and the second low side DC power buses to supply portions of a voltage across the high side DC power bus.

28. The power system of claim 25 wherein the first and the second DC/DC power converters are respective interleaved high power DC/DC boost power converter circuits.

29. The power system of claim 25 wherein the first DC/DC power converter comprises a number of power semiconductor switches, a number of anti-parallel diodes, each of the anti-parallel diodes electrically coupled in anti-parallel across a respective one of the power semiconductor switches, and a number of inductors, each of the inductors electrically coupled between the first lower side DC power bus and a terminal of a respective one of the power semiconductor switches.

30. The power system of claim 29, further comprising:

a controller coupled to control at least some of the power semiconductor switches.

31. The power system of claim 25, further comprising:

a DC/AC power converter electrically coupled to the high side DC power bus and operable to invert a current carried by the high side DC power bus.

32. The power system of claim 31 wherein the DC/AC power converter is bi-directionally operable to provide a rectified current to the high side DC power bus.

33. The power system of claim 31 wherein the DC/AC power converter is a three-phase power converter circuit comprising a first leg comprising a first pair of upper and lower power semiconductor switches, a second leg comprising a second pair of upper and lower power semiconductor switches and a third leg comprising a third pair of upper and a lower power semiconductor switches, and a number of anti-parallel diodes, each of the anti-parallel diodes electrically coupled in anti-parallel across a respective one of the upper and lower power semiconductor switches.

34. The power system of claim 25, further comprising:

a third low side DC/DC converter circuit operable to bi-directionally transform power between the high side DC power bus and an auxiliary power storage device.

35. A method of operating a power system, comprising:

pulling up a potential on a first voltage rail of a high side DC power bus during at least a first period; and

pulling down a potential on a second voltage rail of the high side DC power bus during at least a portion of the first period.

36. The method of claim 35 wherein pulling up a potential on a first voltage rail of a high side DC power bus comprises boost converting a voltage across a first low side DC power bus and wherein pulling down a potential on a second voltage rail of the high side DC power bus comprises boost converting a voltage across a second low side DC power bus, wherein a lower voltage rail of the first low side DC power bus is commonly connected with a higher voltage rail of the second low side DC power bus.

37. The method of claim 35 wherein pulling up a potential on a first voltage rail of a high side DC power bus comprises boost converting a voltage across a first low side DC power bus and wherein pulling down a potential on a second voltage rail of the high side DC power bus comprises boost converting a voltage across a second low side DC power bus, wherein an upper voltage rail of each of the first and the second low side DC power buses are electrically commonly coupled, and wherein a lower voltage rail of each of the first and the second low side DC power buses are electrically commonly coupled.

38. The method of claim 35, further comprising:

inverting a voltage across the first and the second voltage rails of the high side DC power bus during at least a portion of the first period; and

applying the inverted voltage to drive an electric machine.

39. A method of operating a power system, comprising:

in a first mode, operating a first DC/DC power converter circuit to boost a potential on a first voltage rail of a high side DC power bus above a high potential of a first low side DC power bus; and

in the first mode, operating a second DC/DC power converter circuit to boost a potential on a second voltage rail of the high side DC power bus below a low potential of a second low side DC power bus, the first and the second DC/DC power converter circuits electrically coupled in series with each other across the high side DC power bus.

40. The method of claim 39, further comprising:

operating a first DC/AC power converter circuit to invert a current carried by the high side DC power bus.

41. The method of claim 39, further comprising:

operating a first DC/AC power converter circuit in at least one mode to invert a current received via the high side DC power bus; and

operating the first DC/AC power converter circuit in at least another mode to rectify a current supplied to the high side DC power bus.

42. The method of claim 39, further comprising:

operating an auxiliary DC/DC power converter circuit to boost a voltage supplied by an auxiliary power storage device.

43. The method of claim 39, further comprising:

operating an auxiliary power converter circuit to reduce a voltage supplied to an auxiliary power storage device.

44. A method of operating a power system, comprising:

supplying power from a first primary power source to a first low side DC power bus electrically coupled to the first primary power source during a first period;

supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period;

boosting a potential on a first voltage rail of a high side DC power bus above a high potential of the first low side DC power bus during the first period;

boosting a potential on a second voltage rail of the high side DC power bus below a low potential of the second low side DC power bus during at least the portion of the first period;

ceasing the supplying of power from the second primary power source to the second low side DC power bus electrically coupled to the second primary power source during a second period;

continuing the supplying of power from the first primary power source to the first low side DC power bus during the second period; and

boosting the potential on the first voltage rail of the high side DC power bus above the high potential of the first low side DC power bus during the second period.

45. The method of claim 44 wherein continuing the supplying of power from the first primary power source to the first low side DC power bus during the second period comprises supplying a same voltage across the first low side DC power bus during the second period as during the first period.

46. The method of claim 44 wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period comprises supplying a voltage across the first low side DC power bus from a first fuel cell stack of a first fuel cell system;

and wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second power source during at least a portion of the first period comprises supplying a voltage across the second low side DC power bus from a second fuel cell stack of a second fuel cell system.

47. The method of claim 44 wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period comprises supplying a voltage across the first low side DC power bus from a first fuel cell stack of a fuel cell system and wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period comprises supplying a voltage across the second low side DC power bus from a second fuel cell stack of the fuel cell system.

48. The method of claim 44 wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period comprises supplying a voltage across the first low side DC power bus from a portion of a fuel cell stack and wherein supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source during at least a portion of the first period comprises supplying a voltage across the second low side DC power bus from a second portion of the fuel cell stack.

49. The method of claim 44 wherein ceasing the supplying of power from the second primary power source to the second low side DC power bus electrically coupled to the second primary power source during a second period occurs in response to a determination that an operational fault has occurred for the second primary power source.

50. The method of claim 44 wherein ceasing the supplying of power from the second primary power source to the second low side DC power bus electrically coupled to the second primary power source during a second period occurs in response to a determination that a demanded output power is below an output power threshold.

51. The method of claim 44, further comprising:

from time-to-time providing a short circuit path across at least one of the first or second primary power sources.

52. The method of claim 44, further comprising:

determining an ambient temperature at a startup time when starting at least one of the first or the second primary power sources;

determining whether the ambient temperature is below a threshold temperature; and

providing a short circuit path across at least one of the first or second primary power sources in response to the ambient temperature being below the threshold temperature at the startup time.

53. A power system, comprising:

a first multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the first multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another; and

a second multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the second electrically conductive layer of the second multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another, the second multi-layer substrate positioned overlying at least a portion of the first multi-layer substrate, at least one of the regions of the second electrically conductive layer of the second multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the first multi-layer substrate.

54. The power system of claim 53 wherein any one of the regions of the second electrically conductive layer of the second multi-layer substrate are electrically coupled to fewer than two of the regions of the first electrically conductive layer of the first multi-layer substrate thereby preventing a short circuit path between the regions of the first electrically conductive layer of the first multi-layer substrate.

55. The power system of claim 54, further comprising:

a first number of switches surface mounted to at least some of the regions of the first electrically conductive layer of the first multi-layer substrate.

56. The power system of claim 55 wherein the first number of switches form at least a portion of at least one phase leg of a DC/AC power converter.

57. The power system of claim 55, further comprising:

a second number of switches surface mounted at least some of the regions of the first electrically conductive layer of the first multi-layer substrate.

58. The power system of claim 57 wherein the first number of switches form at least a portion of at least one phase leg of a DC/AC power converter and wherein the second number of switches form at least a portion of at least one phase of a DC/DC power converter.

59. The power system of claim 53 wherein the electrically insulative layer of the second multi-layer substrate forms at least one via therethrough, and further comprising:

a conductive material received in the at least one via to electrically couple at least one of the regions of the first electrically conductive layer of the second multi-layer substrate with at least one of the regions of the first electrically conductive layer of the first multi-layer substrate by way of at least one of the regions of the second electrically conductive layer of the second multi-layer substrate.

60. The power system of claim 53, further comprising:

a third multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer is patterned to form a number of regions, the regions electrically isolated from one another, at least a portion of the second multi-layer substrate positioned overlying at least a portion of the third multi-layer substrate, at least one region of the second electrically conductive layer of the second multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the third multi-layer substrate; and

a first number of switches surface mounted to at least some of the regions of the first electrically conductive layers of the first and the third multi-layer substrates, wherein the first number of switches form at least one phase leg of a DC/AC power converter.

61. The power system of claim 60 further comprising:

a second number of switches surface mounted at least some of the regions of the first electrically conductive layer of the first multi-layer substrate, wherein the second number of switches form at least a portion of at least one phase of a DC/DC power converter.

62. The power system of claim 60 wherein the first multi-layer substrate is approximately planar, the second multi-layer substrate is approximately planar, the third multi-layer substrate is approximately planar, and the second multi-layer substrate is spaced normally from the first and the third multi-layer substrates.

63. The power system of claim 62 wherein the first and the third multi-layer substrates are each elongated and at least approximately parallel to one another.

64. The power system of claim 63 wherein the second multi-layer substrate is elongated and is positioned perpendicularly across both the first and the third multi-layer substrates, the second electrically conductive layers of the first and the third multi-layer substrates each soldered to the first electrically conductive layer of the second multi-layer substrate.

65. The power system of claim 64 wherein the insulative layer of the second multi-layer substrate forms at least one via therethrough, and further comprising:

a conductive material received in the at least one via to electrically couple at least one of the regions of the first electrically conductive layer of the second multi-layer substrate with at least one of the regions of the first electrically conductive layers on each of the first, and the third multi-layer substrates by way of at least one of the regions of the second electrically conductive layer of the second multi-layer substrate.

66. The power system of claim 53, further comprising:

a third multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the third multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another, at least a portion of the second multi-layer substrate positioned overlying at least a portion of the third multi-layer substrate, at least one region of the second electrically conductive layer of the second multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the third multi-layer substrate;

a fourth multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the fourth multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another, at least a portion of the second multi-layer substrate positioned overlying at least a portion of the fourth multi-layer substrate, at least one region of the second electrically conductive layer of the second multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the fourth multi-layer substrate;

a fifth multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the fifth multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another, at least a portion of the second multi-layer substrate positioned overlying at least a portion of the fifth multi-layer substrate, at least one region of the second electrically conductive layer of the second multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the fifth multi-layer substrate; and

a first number of switches surface mounted to at least some of the regions of the first electrically conductive layers of the first, the third, the fourth, and the fifth multi-layer substrates, wherein the first number of switches form at least one phase leg of a DC/AC power converter and at least one phase leg of a DC/DC power converter.

67. The power system of claim 66 wherein the insulative layer of the second multi-layer substrate forms at least one via therethrough, and further comprising:

a conductive material received in the at least one via to electrically couple at least one of the regions of the first electrically conductive layer of the second multi-layer substrate with at least one of the regions of the first electrically conductive layers on each of the first, the third, the fourth, and the fifth multi-layer substrates by way of at least one of the regions of the second electrically conductive layer of the second multi-layer substrate.

68. A power system, comprising:

a first DC/AC converter multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the first DC/AC converter multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another;

a second DC/AC converter multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the second DC/AC converter multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another;

a first number of switches surface mounted to at least some of the regions of the first electrically conductive layers of the first and the second DC/AC converter multi-level substrates to form at least one phase leg of a DC/AC converter;

a DC/DC converter multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers and forming at least one via therethrough, wherein the first and the second electrically conductive layers of the DC/DC converter multi-layer substrate are patterned to form a number of regions, the regions on first electrically conductive layer electrically isolated from one another and the regions on the second electrically conductive layer electrically isolated from one another, the second electrically conductive layer of the DC/DC converter multi-layer substrate opposed to at least a portion of the first electrically conductive layers of the first and the second DC/AC converter multi-layer substrates, at least one of the regions of the second electrically conductive layer of the DC/DC converter multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the first and the second DC/AC converter multi-layer substrates; and

a conductive material received in the at least one via to electrically couple at least one of the regions of the first electrically conductive layer of the DC/DC converter multi-layer substrate with at least one of the regions of the first electrically conductive layers on each of the first and the second DC/AC converter multi-layer substrates by way of at least one of the regions of the second electrically conductive layer of the DC/DC converter multi-layer substrate.

69. The power system of claim 68 wherein the first electrically conductive layer of the DC/DC converter multi-level substrate is patterned to form a number of regions, the regions of the DC/DC converter multi-level substrate electrically isolated from one another, and further comprising:

a second number of switches surface mounted to at least some of the regions of the first electrically conductive layers of the DC/DC converter multi-level substrate.

70. The power system of claim 68 wherein the DC/DC converter multi-level substrate is a die bonded copper substrate.

71. The power system of claim 68 wherein the DC/DC converter multi-level substrate is a die bonded copper substrate.

72. The power system of claim 68, further comprising:

a third DC/AC converter multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the second electrically conductive layers, wherein the first electrically conductive layer of the third DC/AC converter multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another; and

a fourth DC/AC converter multi-layer substrate comprising at least a first electrically conductive layer, a second electrically conductive layer and an electrically insulative layer positioned between the first and the fourth electrically conductive layers, wherein the first electrically conductive layer of the fourth DC/AC converter multi-layer substrate is patterned to form a number of regions, the regions electrically isolated from one another, and wherein the second electrically conductive layer of the DC/DC converter multi-layer substrate is opposed to at least a portion of the first electrically conductive layers of the third and the fourth DC/AC converter multi-layer substrates, at least one of the regions of the second electrically conductive layer of the DC/DC converter multi-layer substrate electrically coupled to at least one of the regions of the first electrically conductive layer of the third and the fourth DC/AC converter multi-layer substrates.

73. A power system, comprising:

a first primary direct current to direct current (DC/DC) power converter coupled between a first voltage rail of a high voltage direct current (DC) power system and a positive voltage bus of a low voltage DC power system such that the first primary DC/DC power converter controls a voltage difference between the first voltage rail and the positive voltage bus; and

a second primary DC/DC power converter serially connected to the first primary DC/DC power converter and coupled between a second voltage rail of the high voltage DC power system and a negative voltage bus of the low voltage DC power system such that the second primary DC/DC power converter controls a voltage difference between the second voltage rail and the negative voltage bus.

74. The power system of claim 73 wherein the voltage difference between the first voltage rail and the positive voltage bus is independently controllable from the voltage difference between the second voltage rail and the negative voltage bus.

75. The power system of claim 73, further comprising:

a neutral node operable at a neutral voltage, wherein the neutral voltage is between a voltage of the positive voltage bus and a voltage of the negative voltage bus;

a first capacitor coupled between the neutral node and the first voltage rail; and

a second capacitor coupled between the neutral node and the second voltage rail.

76. The power system of claim 75 wherein a first DC source and a second DC source are coupled in series, and wherein the neutral node is coupled between the first DC source and the second DC source.

77. The power system of claim 76 wherein the neutral node is coupled to a negative terminal of the first DC source and a positive terminal of the second DC source.

78. The power system of claim 75 wherein the first primary DC/DC power converter comprises:

a first inductor coupled to a positive terminal of a first DC source;

a first switch coupled between the neutral node and the first inductor; and

a first diode coupled between the first inductor and the first voltage rail, and wherein the second primary DC/DC power converter comprises;

a second inductor coupled to a negative terminal of a second DC source;

a second switch coupled between the neutral node and the second inductor; and

a second diode coupled between the second inductor and the second voltage rail, such that DC power is transferable from the first and the second DC sources to the high voltage DC power system by operation of the first and second switches.

79. The power system of claim 75 wherein the first primary DC/DC power converter comprises:

a first inductor coupled to a positive terminal of a first DC source;

a first switch coupled between the neutral node and the first inductor; and

a second switch coupled between the first inductor and the first voltage rail, and wherein the second primary DC/DC power converter comprises;

a second inductor coupled to a negative terminal of a second DC source;

a third switch coupled between the neutral node and the second inductor; and

a fourth switch coupled between the second inductor and the second voltage rail, such that power is transferable from the first and the second DC sources to the high voltage DC power system by operation of the first and third switches, and such that power is transferable from the high voltage DC power system to the first and the second DC sources by operation of the second and fourth switches.

80. A power system, comprising:

a first voltage rail operable at a first direct current (DC) voltage;

a second voltage rail operable at a second DC voltage;

a neutral node operable at a neutral voltage that is between the first DC voltage and the second DC voltage, the neutral node coupled to a negative terminal of a first source and coupled to a positive terminal of a second source;

a first primary direct current to direct current (DC/DC) power converter, comprising

a first inductor coupled to the positive terminal of the first source;

a first switch coupled between the neutral node and the first inductor; and

a first diode coupled between the first inductor and the first voltage rail;

a second primary DC/DC power converter, comprising

a second inductor coupled to a negative terminal of the second source;

a second switch coupled between the neutral node and the second inductor; and

a second diode coupled between the second inductor and the second voltage rail;

a first capacitor coupled between the first voltage rail and the neutral node; and

a second capacitor coupled between the second voltage rail and the neutral node.

81. The power system of claim 80 wherein the first source is operable at a first source voltage and the second source is operable at a second source voltage, and wherein a sum of the first DC voltage and the second DC voltage is greater than a sum of the first source voltage and the second source voltage.

82. The power system of claim 80 wherein the first source is operable at a first source voltage and the second source is operable at a second source voltage, and wherein a sum of the first DC voltage and the second DC voltage is less than a sum of the first source voltage and the second source voltage.

83. The power system of claim 80 wherein the first source is operable at a first source voltage (V₁) and the second source is operable at a second source voltage (V₂), and further comprising:

a controller operable to actuate the first switch and the second switch for a duty cycle (D), wherein a DC voltage (V_DC) corresponding to a sum of the first DC voltage of the first voltage rail and the second DC voltage of the second voltage rail is (V_DC)=(V₁+V₂)/(1−

D).

84. The power system of claim 83 wherein the first source voltage and the second source voltage are equal, and the controller is operable to actuate the first switch and the second switch for the same duty cycle.

85. The power system of claim 83 wherein the controller is operable to actuate the first switch for a first duty cycle and is operable to actuate the second switch for a second duty cycle, wherein the first duty cycle is different from the second duty cycle, such that the first source voltage and the second source voltage are different.

86. The power system of claim 80 wherein the first inductor, the first switch, and the first diode are electrically coupled to form a first converter leg, and wherein the second inductor, the second switch, and the second diode are electrically coupled to form a second converter leg.

87. The power system of claim 86 wherein the first primary DC/DC power converter further comprises:

a third converter leg, and wherein the second primary DC/DC power converter further comprises;

a fourth converter leg, wherein each of the third and fourth converter legs have an inductor, a switch, and a diode.

88. The power system of claim 86 wherein the first primary DC/DC power converter further comprises:

a plurality of additional first converter legs, and wherein the second primary DC/DC power converter further comprises;

a plurality of additional second converter legs, wherein each of the additional first and second converter legs have an inductor, a switch and a diode.

89. The power system of claim 88 wherein a number of the additional first converter legs of the first primary DC/DC power converter is different from a number of the additional second converter legs of the second primary DC/DC power converter.

90. The power system of claim 80, further comprising:

a third primary DC/DC power converter, comprising

a third inductor coupled to the positive terminal of the first source;

a third switch coupled between the neutral node and the third inductor; and

a third diode coupled between the third inductor and the first voltage rail; and

a fourth primary DC/DC power converter, comprising

a fourth inductor coupled to the negative terminal of the second source;

a fourth switch coupled between the neutral node and the fourth inductor; and

a fourth diode coupled between the fourth inductor and the second voltage rail.

91. The power system of claim 80, further comprising:

a plurality of additional first primary DC/DC power converters, each additional first primary DC/DC power converter comprising a first additional inductor coupled to the positive terminal of the first source, a first additional switch coupled between the neutral node and the respective inductor, and a first additional diode coupled between the respective inductor and the first voltage rail; and

a plurality of additional second primary DC/DC power converters, each additional second primary DC/DC power converter comprising a second additional inductor coupled to the negative terminal of the second source, a second additional switch coupled between the neutral node and the respective inductor, and a second additional diode coupled between the respective inductor and the second voltage rail.

92. The power system of claim 91 wherein a number of the first primary DC/DC power converters is different from a number of the second primary DC/DC power converters.

93. A power system, comprising:

a first primary direct current to direct current (DC/DC) power converter coupled between a first voltage rail operable at a first direct current (DC) voltage and a positive terminal of a first DC source, comprising;

a first inductor coupled to the positive terminal of the first DC source;

a first switch coupled between a neutral node and the first inductor; and

a second switch coupled between the first inductor and the first voltage rail; and

a second primary DC/DC power converter coupled between a second voltage rail operable at a second DC voltage and a negative terminal of a second DC source, comprising

a second inductor coupled to the negative terminal of the second DC source;

a third switch coupled between the neutral node and the second inductor; and

a fourth switch coupled between the second inductor and the second voltage rail.

94. The power system of claim 93 wherein:

the first switch conducts DC current from the first DC source to the first voltage rail;

the second switch conducts DC current from the first voltage rail to the first DC source;

the third switch conducts DC current from the second DC source to the second voltage rail; and

the first switch conducts DC current from the second voltage rail to the second DC source.

95. The power system of claim 94, further comprising:

a third primary DC/DC power converter coupled between the first voltage rail and the positive terminal of the first DC source, comprising;

a third inductor coupled to the positive terminal of the first DC source;

a fifth switch coupled between the neutral node and the third inductor; and

a first diode coupled between the third inductor and the first voltage rail; and

a fourth primary DC/DC power converter coupled between the second voltage rail and the negative terminal of the second DC source, comprising

a fourth inductor coupled to the negative terminal of the second DC source;

a sixth switch coupled between the neutral node and the fourth inductor; and

a second diode coupled between the fourth inductor and the second voltage rail,

wherein the third switch conducts DC current from the first DC source to the first voltage rail, wherein the first diode blocks DC current from the first voltage rail to the first DC source, wherein the fourth switch conducts DC current from the second DC source to the second voltage rail, and wherein the second diode blocks DC current from the second voltage rail to the second DC source.

96. The power system of claim 95 wherein a capacity from the first and second sources to the first and second voltage rails is greater than a capacity from the first and second voltage rails to the first and second sources.

97. The power system of claim 93, further comprising:

the neutral node operable at a neutral voltage that is between a first DC voltage and the second DC voltage, the neutral node coupled to the negative terminal of the first DC source and coupled to the positive terminal of the second DC source;

a first capacitor coupled between the first voltage rail and the neutral node; and

a second capacitor coupled between the second voltage rail and the neutral node.

98. A power system, comprising:

a high voltage side having a high voltage rail operable at a first direct current (DC) voltage and a low voltage rail operable at a second DC voltage;

a low voltage side;

a traction drive electrically coupled to the high voltage side without an intervening power converter;

a fuel cell system electrically coupleable to the high voltage side to provide power to the traction drive; and

a DC/DC power converter system electrically coupling the low voltage side to the high voltage side of the power system, wherein the DC/DC power converter system further comprises;

a first primary DC/DC power converter; and

a second primary DC/DC power converter serially connected to the first primary DC/DC power converter,

such that the first primary DC/DC power converter is coupled between the high voltage rail and a positive terminal of the low voltage side, and such that the second primary DC/DC power converter is coupled between the low voltage rail and a negative terminal of the low voltage side.

99. The power system of claim 98, further comprising:

at least one high voltage auxiliary electrically coupled to the fuel cell system without the intervening power converter.

100. The power system of claim 98, further comprising:

a low voltage battery having a positive terminal coupled to the positive terminal of the low voltage side and having a negative terminal coupled to the negative terminal of the low voltage side such that DC power is transferred between the low voltage battery and the high voltage side of the power system through the DC/DC power converter system.

101. The power system of claim 98, further comprising:

a high voltage power storage device;

a second DC/DC power converter system electrically coupling the high voltage power storage device to the high voltage side of the power system, wherein the second DC/DC power converter system further comprises;

a third primary DC/DC power converter; and

a fourth primary DC/DC power converter serially connected to the third primary DC/DC power converter,

such that the third primary DC/DC power converter is coupled between the first voltage rail and the positive terminal of the high voltage power storage device, and such that the fourth primary DC/DC power converter is coupled between the second voltage rail and the negative terminal of the high voltage power storage device.

102. The power system of claim 98 wherein the fuel cell system is directly coupled to the high voltage side to provide power directly to the traction drive via the high voltage side.

103. The power system of claim 98, further comprising:

a second DC/DC power converter system electrically coupling a high voltage power storage device to the high voltage side of the power system, wherein the DC/DC power converter system further comprises;

a third primary DC/DC power converter; and

a fourth primary DC/DC power converter serially connected to the third primary DC/DC power converter,

such that the third primary DC/DC power converter is coupled between the high voltage rail and the positive terminal of the fuel cell system, and such that the fourth primary DC/DC power converter is coupled between the low voltage rail and the negative terminal of the fuel cell system.

104. A method of operating a power system, comprising:

supplying power from a first primary power source to a first low side direct current (DC) power bus electrically coupled to the first primary power source;

supplying power from a second primary power source to a second low side DC power bus electrically coupled to the second primary power source;

pulling up voltage from the first primary power source to a positive high voltage on a first voltage rail of a high side DC power bus; and

pulling down voltage from the second primary power source to a negative high voltage on a second voltage rail of the high side DC power bus.

105. The method of claim 104, further comprising:

selecting one of the first primary power source and the second primary power source; and

reducing power supplied from the selected one of the first or the second primary power sources so that the selected one of the first or the second primary power sources is operating in an idling mode.

106. The method of claim 104, further comprising:

selecting one of the first primary power source and the second primary power source; and

ending the supplying of the power from the selected one of the first or the second primary power sources so that the selected one of the first or the second primary power sources is operating in a sleeping mode; and

operating the non-selected one of the first or the second primary power sources at a higher voltage level.

107. The method of claim 106, wherein operating the non-selected one of the first or the second primary power sources at the higher voltage level further comprises operating the non-selected one of the first or the second primary power sources at a maximum voltage level.

108. The method of claim 104, further comprising:

operating at a reduced voltage at least one of the first primary power source or the second primary power source so that waste heat is generated for a cold start.

109. A method of operating a power system, comprising:

stepping up a positive DC voltage of a first primary power source to a higher positive DC voltage; and

stepping down a negative DC voltage of a second primary power source to a lower negative DC voltage,

wherein the first primary power source and the second primary power source are serially connected.

110. The method of claim 109, further comprising:

transmitting power over a first low side DC power bus electrically coupled to the first primary power source; and

transmitting power over a second low side DC power bus electrically coupled to the second primary power source.

111. The method of claim 110, further comprising:

receiving power from the first primary power source and the second primary power source;

actuating a first switch of a first primary DC/DC power converter to transmit the received power from the first primary power source to a high voltage rail having the higher positive DC voltage; and

actuating a second switch of a second primary DC/DC power converter to transmit the received power from the second primary power source to a low voltage rail having the lower negative DC voltage.

112. The method of claim 110, further comprising:

de-actuating a first switch of a first primary DC/DC power converter and a second switch of a second primary DC/DC power converter;

receiving power via a high voltage rail having the higher positive DC voltage;

receiving power via a low voltage rail having the lower negative DC voltage;

switching a third switch of the first primary DC/DC power converter to transmit power received via the high voltage rail to the first primary power source; and

switching a fourth switch of the second primary DC/DC power converter to transmit the power received via the low voltage rail to the second primary power source.

113. The method of claim 109, further comprising:

switching a first switch of a first primary DC/DC power converter to step up the positive DC voltage to the higher positive DC voltage; and

switching a second switch of a second primary DC/DC power converter to convert the negative DC voltage to the lower negative DC voltage.

114. The method of claim 109, further comprising:

protecting the first primary power source with a first diode of a first primary DC/DC power converter; and

protecting the second primary power source with a second diode of a second primary DC/DC power converter,

wherein the first and second diodes block voltage and current changes occurring on a load side of the power system coupled to the first and the second primary DC/DC power converters.

115. A method of operating a first primary power source and a second primary power source, comprising:

initially generating power from the first primary power source and the second primary power source, wherein the first primary power source and the second primary power source are serially connected;

initially stepping up a positive DC voltage of the first primary power source to a higher positive DC voltage;

initially stepping down a negative DC voltage of the second primary power source to a lower negative DC voltage;

reducing power generated by the second primary power source; and

further stepping up the positive DC voltage of the first primary power source to a second higher positive DC voltage.

116. The method of claim 115, further comprising:

selecting one of the first primary power source and the second primary power source; and

reducing power supplied from the selected one of the first or the second primary power sources so that the selected one of the first or the second primary power sources is operating in an idling mode.

117. The method of claim 115, further comprising:

selecting one of the first primary power source and the second primary power source;

ending the generation of the power from the selected one of the first or the second primary power sources so that the selected one of the first or the second primary power source is operating in a sleeping mode; and

operating the non-selected one of the first or the second primary power sources at a second higher voltage level.

118. The method of claim 117, wherein operating the non-selected one of the first or the second primary power sources at a higher voltage level further comprises operating the non-selected-one of the first or the second primary power sources at a maximum voltage level.

119. The method of claim 115, further comprising:

reducing the negative DC voltage of the second primary power source; and

generating waste heat from the second primary power source for a cold start.