DC-DC converter, DC power distribution system, and method for converting DC voltage using DC-DC converter

Abstract

A DC-DC converter, a DC power distribution system, and a method of converting a DC voltage using the DC-DC converter are provided. An example DC-DC converter includes a housing having at least two bullet type terminals. The at least two cartridge terminals are configured to mate with corresponding terminals in a DC cartridge circuit breaker panel. The converter also includes a DC-DC voltage converter circuit coupled between the at least two bullet terminals, and a controller coupled with the DC-DC voltage converter circuit. The controller is configured to control the DC-DC converter circuit to convert a DC input voltage at a first one of the at least two bullet terminals to a different DC output voltage at the other one of the at least two bullet terminals.

Description

[0001] This application is a divisional application of a Chinese patent application filed on April 10, 2018, with international application number PCT / US2018 / 026905, invention name “DC-DC converter with bullet-type terminals”, and application number 201880023714.0 after entering the Chinese national phase.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of and priority to U.S. Provisional Application No. 62 / 483,622, filed on April 10, 2017. The entire disclosure of the above application is incorporated herein by reference. Technical Field

[0004] The present disclosure relates to a DC-DC converter having bullet terminals and a method of converting a DC voltage using a DC-DC converter having bullet terminals. Background Art

[0005] This section provides background information related to the present disclosure which is not necessarily prior art.

[0006] Wireless service providers use power radios located on radio towers at various heights. Due to the length of the cable loop from the power system to the radio, the DC voltage at the radio is reduced, and the DC voltage also decreases during AC outages (due to battery discharge). Wireless providers typically deploy independent DC-DC converter systems connected to existing -48VDC rectifier / battery plants to increase the DC output voltage to the radio to allow the radio to maintain operation during outages and reduce the size of the cables that power the remote radios. In addition, distributed antenna system (DAS) providers sometimes deploy independent Class 2 circuit converter systems that limit each circuit to 100W. However, the installation of independent converter systems requires considerable additional costs as well as additional rack space. Summary of the invention

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope and all of its features.

[0008] According to one aspect of the present disclosure, a DC-DC converter includes a housing having at least two bullet terminals. The at least two bullet terminals are configured to mate with corresponding terminals in a DC bullet breaker panel. The converter also includes a DC-DC voltage converter circuit coupled between the at least two bullet terminals, and a controller coupled to the DC-DC voltage converter circuit. The controller is configured to control the DC-DC converter circuit to convert a DC input voltage at a first bullet terminal of the at least two bullet terminals to a different DC output voltage at another bullet terminal of the at least two bullet terminals.

[0009] According to another aspect of the present disclosure, a method for converting a DC voltage using a DC-DC converter is disclosed. The DC-DC converter includes a housing having at least two bullet terminals. The at least two bullet terminals are configured to cooperate with corresponding terminals of a DC bullet breaker panel. The device also includes a DC-DC converter circuit coupled between the at least two bullet terminals and a controller coupled to the DC-DC converter circuit. The method includes: receiving a DC input voltage from one of the corresponding terminals of the DC bullet breaker panel at a first bullet terminal of the at least two bullet terminals, and converting the received DC input voltage to a different DC output voltage using the DC-DC converter circuit. The method also includes supplying the converted DC output voltage to another terminal of the corresponding terminals of the DC bullet breaker panel via another bullet terminal of the at least two bullet terminals.

[0010] According to another aspect of the present disclosure, a DC-DC converter is disclosed, comprising: a housing having at least two bullet terminals, the at least two bullet terminals being configured to cooperate with corresponding terminals in a DC bullet breaker panel, the DC-DC converter being inserted into the DC bullet breaker panel via the at least two bullet terminals, the at least two bullet terminals comprising paired bullet terminals; a DC-DC voltage converter circuit coupled between the at least two bullet terminals; a controller coupled to the DC-DC voltage converter circuit, the controller being configured to control the DC-DC voltage converter circuit to convert a DC input voltage at a first bullet terminal in the paired bullet terminals into a different DC output voltage at another bullet terminal in the paired bullet terminals; an overcurrent protection circuit coupled between the at least two bullet terminals, the overcurrent protection A circuit is configured to protect the DC-DC converter from an overcurrent condition; a fault protection circuit coupled between the paired bullet terminals to disconnect the at least two bullet terminals to create an open circuit when a fault condition of the DC-DC converter is detected; a power and current limiter circuit coupled between the DC-DC voltage converter circuit and the overcurrent protection circuit, the power and current limiter circuit being configured to limit the DC output power of the DC-DC converter to below a specified output power threshold and to limit the DC output current of the DC-DC converter to below a specified output current threshold, the power and current limiter circuit including a power and current limiting circuit topology; and a backup overcurrent protection circuit that creates a physical disconnect between the at least two bullet terminals in the event that the overcurrent protection provided by the overcurrent protection circuit is insufficient to adequately limit the DC output current.

[0011] According to another aspect of the present disclosure, a DC power distribution system is disclosed, which includes the above-mentioned DC-DC converter, and the DC power distribution system also includes a DC bullet-type circuit breaker panel having at least two bullet-type terminals, wherein the at least two bullet-type terminals of the DC-DC converter are coupled to the at least two bullet-type terminals of the DC bullet-type circuit breaker panel.

[0012] According to another aspect of the present disclosure, a method for converting a DC voltage using a DC-DC converter is also disclosed, the DC-DC converter comprising a housing having at least two bullet terminals, a DC-DC voltage converter circuit coupled between the at least two bullet terminals, a power and current limiter circuit coupled between the DC-DC voltage converter circuit and an overcurrent protection circuit, and a controller coupled to the DC-DC voltage converter circuit, the at least two bullet terminals being configured to mate with corresponding terminals in a DC bullet breaker panel, and the at least two bullet terminals comprising paired bullet terminals, the method comprising: receiving a DC input voltage from one of the corresponding terminals of the DC bullet breaker panel at a first bullet terminal in the paired bullet terminals; converting the received DC input voltage into a different DC output voltage through the DC-DC voltage converter circuit; and converting the converted DC output voltage into a different DC output voltage through a second bullet terminal in the paired bullet terminals. C output voltage is supplied to another terminal of the corresponding terminals of the DC bullet breaker panel; the DC output power supplied by the DC-DC converter at the second bullet terminal is limited to below a specified output power threshold by the power and current limiter circuit, and the DC output current supplied by the DC-DC converter at the second bullet terminal is limited to below a specified output current threshold, the power and current limiter circuit including a power and current limiting circuit topology; when a fault condition of the DC-DC converter circuit is detected, the at least two bullet terminals are disconnected to produce an open circuit by a fault protection circuit coupled between the paired bullet terminals; and the overcurrent protection circuit is controlled to protect the DC-DC converter from an overcurrent condition, wherein in the event that the overcurrent protection provided by the overcurrent protection circuit is insufficient to fully limit the DC output current, a physical disconnection is produced between the at least two bullet terminals by a backup overcurrent protection circuit.

[0013] According to the description provided herein, other aspects and applicable fields will become apparent. It should be understood that the various aspects and features of the present disclosure can be realized individually or in combination with one or more other aspects or features. It should also be understood that the description and specific examples herein are only for illustrative purposes and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0015] Figure 1 is a block diagram of a DC-DC converter according to an example embodiment of the present disclosure.

[0016] Figure 2 is a block diagram of a DC-DC converter having a power and / or current limiter circuit and an overcurrent protection circuit according to another example embodiment of the present disclosure.

[0017] Figure 3 is a perspective view of a DC-DC converter including a bullet-type connector converter housing according to another example embodiment of the present disclosure.

[0018] Figure 4 is a perspective view of another DC-DC converter including a bullet-type connector toggle handle circuit breaker housing according to another example embodiment of the present disclosure.

[0019] Figure 5 is a perspective view of another DC-DC converter including a bullet-type connector fuseholder housing according to another example embodiment of the present disclosure.

[0020] Corresponding reference numerals indicate corresponding features throughout the several views of the drawings. DETAILED DESCRIPTION

[0021] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0022] Example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope to those skilled in the art. Many specific details, such as examples of specific components, devices and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that these specific details need not be adopted, and that the example embodiments can be implemented in many different forms, and neither should be construed as limiting the scope of the present disclosure. In some example embodiments, known processes, known device structures and known technologies are not described in detail.

[0023] The terms used herein are only used to describe the purpose of specific example embodiments and are not intended to be limiting. As used herein, unless the context clearly indicates otherwise, the singular forms "one", "an", "the" may also be intended to include plural forms. The terms "include", "comprise", "contain", and "have" are inclusive, and therefore specify the presence of the features, integers, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or their groups. Unless specifically identified as an execution order, the method steps, processes, and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown. It should also be understood that additional or alternative steps may be adopted.

[0024] Although the terms first, second, third, etc. can be used in this article to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or part from another region, layer or part. Unless the context clearly indicates, the terms such as "first", "second" and other numerical terms used in this article do not mean order or sequence. Therefore, without departing from the teaching of the example embodiments, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part.

[0025] Spatially relative terms, such as "inside", "outside", "under", "below", "lower", "above", "upper", etc., may be used herein to facilitate the description of the relationship between an element or feature and another (additional) element or feature as shown in the figure. In addition to the orientation depicted in the figure, spatially relative terms may be intended to include different orientations of the device in use or operation. For example, if the device in the figure is flipped, the elements described as "below" or "below" other elements or features will be oriented "above" other elements or features. Therefore, the example term "below" may include orientations above and below. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially related descriptors used in this article may be interpreted accordingly.

[0026] A DC-DC converter according to an example embodiment of the present disclosure is Figure 1 100. Figure 1 As shown, the DC-DC converter 100 includes a housing 102 having a pair of bullet terminals 104 and 106. The bullet terminals 104 and 106 are configured to mate with corresponding terminals in a DC bullet breaker panel.

[0027] The DC-DC converter 100 also includes a DC-DC voltage converter circuit 108 coupled between the bullet terminal 104 and the bullet terminal 106, and a controller 110 coupled to the DC-DC voltage converter circuit 108. The controller 110 is configured to control the DC-DC voltage converter circuit 108 to convert a DC input voltage at the bullet terminal 104 to a different DC output voltage at the bullet terminal 106.

[0028] For example, if bullet terminal 104 is an input terminal (e.g., a bullet-type line terminal, etc.) and bullet terminal 106 is an output terminal (e.g., a bullet-type load terminal, etc.), the DC-DC voltage converter circuit 108 can convert a DC input voltage received at bullet terminal 104 to a different DC output voltage at bullet terminal 106.

[0029] As described above, bullet terminals 104 and bullet terminals 106 are configured to mate with corresponding terminals in a DC bullet breaker panel. For example, the size and spacing of bullet terminals 104 and 106 can be set substantially the same as a bullet DC breaker. As used herein, "bullet DC breaker" can refer to any circuit breaker with a bullet terminal configured to be inserted into a DC bullet breaker panel, any fuse with a bullet terminal, etc.

[0030] In some cases, housing 102 can have substantially the same form factor as a bullet-style DC breaker. For example, housing 102 can have the same shape as a bullet-style DC breaker, the same size as a bullet-style DC breaker, etc. Thus, housing 102 and bullet-style terminals 104 and 106 can form a DC-DC converter package that can be inserted into a DC bullet-style breaker panel via bullet-style terminals 104 and 106.

[0031] The DC-DC voltage converter circuit 108 may include any suitable DC-DC converter topology, such as a switching power supply (e.g., a switch mode power supply (SMPS)). The DC-DC voltage converter circuit 108 may include one or more switches, one or more diodes, one or more capacitors, a transformer, etc. The controller 110 may be configured to control the switching operation of the DC-DC voltage converter circuit 108.

[0032] The DC-DC voltage converter circuit 108 can be configured to convert a DC input voltage within any suitable specified voltage input range to a DC output voltage within any suitable specified voltage output range. For example, in some embodiments, the specified DC voltage input range is approximately -42VDC to -58VDC. In this case, the DC-DC voltage converter circuit 108 can convert the DC voltage input to a DC voltage output in the range of approximately -48V to -72VDC.

[0033] In other embodiments, the DC-DC voltage converter circuit 108 may receive a positive DC input voltage at the bullet terminal 104 and provide a positive DC output voltage at the bullet terminal 106, may receive a positive DC input voltage at the bullet terminal 104 and provide a negative DC output voltage at the bullet terminal 106, may receive a negative DC input voltage at the bullet terminal 104 and provide a positive DC output voltage at the bullet terminal 106, etc. The DC-DC voltage converter circuit 108 may receive, convert, and provide DC voltages outside of the ranges listed above.

[0034] Figure 2 A DC-DC converter 200 according to another example embodiment of the present disclosure is shown. The DC-DC converter 200 includes a housing 202 having a pair of bullet terminals 204 and 206 .

[0035] Housing 202 and bullet terminals 204 and 206 may form a DC-DC converter package that may mate with a DC bullet breaker panel via bullet terminals 204 and 206. For example, a DC bullet breaker panel in a DC power distribution system may include bullet terminals for mating with bullet DC breakers, and bullet terminals 204 and 206 of DC-DC converter 200 may be coupled with the bullet terminals of the DC breaker panel.

[0036] The DC-DC converter 200 further includes a DC-DC voltage converter circuit 208 coupled between the bullet terminal 204 and the bullet terminal 206, and a controller 210 coupled to the DC-DC voltage converter circuit 208. The controller 210 is configured to control the DC-DC voltage converter circuit 208 to convert the DC voltage.

[0037] like Figure 2 As shown, the DC-DC converter 200 includes a power and / or current limiter circuit 212 coupled between the bullet terminal 204 and the bullet terminal 206 for limiting the DC output power and / or DC output current of the DC-DC converter 200. For example, the power and / or current limiter circuit 212 can be configured to limit the DC output power at the bullet terminal 206 below a specified output power threshold, limit the DC output current at the bullet terminal 206 below a specified output current threshold, limit both the DC output power and the DC output current, and so on.

[0038] The power and / or current limiter circuit 212 may include any suitable power and / or current limiting circuit topology (eg, inrush current limiter, etc.) The power and / or current limiter circuit 212 may include one or more resistors, switches, diodes, negative temperature coefficient (NTC) thermistors, etc.

[0039] The DC-DC converter 200 also includes an overcurrent protection circuit 214 coupled between the bullet terminal 204 and the bullet terminal 206 for protecting the DC-DC converter 200 from an overcurrent condition. For example, the overcurrent protection circuit 214 can be configured to inhibit the DC output current at the bullet terminal 206 from exceeding an overcurrent condition threshold that may damage the DC-DC converter 200.

[0040] The overcurrent protection circuit 214 may include any suitable overcurrent protection circuit topology. For example, the overcurrent protection circuit 214 may include one or more circuit breakers, fuses, resistors, switches, diodes, etc.

[0041] In addition to the primary overcurrent protection provided by the overcurrent protection circuit 214, the DC-DC converter 200 may also include a backup overcurrent function (e.g., a backup overcurrent protection circuit, a switch, etc.). The backup overcurrent function may create a physical disconnect (e.g., an air gap, etc.) between the bullet terminal 204 and the bullet terminal 206 in the event that the overcurrent protection circuit 214 is insufficient to adequately limit the output current.

[0042] although Figure 2 A power and / or current limiter circuit 212 and a separate overcurrent protection circuit 214 are shown, other embodiments may combine the power limiter circuit, the current limiter circuit, and the overcurrent protection circuit into a single circuit. Alternatively, the power limiter circuit, the current limiter circuit, and the overcurrent protection circuit may each be independent of each other. In some cases, the DC-DC converter may include only one or two of the power limiter circuit, the current limiter circuit, and the overcurrent protection circuit, which may be combined or independent of each other.

[0043] As described above, the DC-DC converter 200 includes a controller 210. The controller 210 is shown coupled to the DC-DC voltage converter circuit 208, the power or current limiter circuit 212, and the overcurrent protection circuit 214. However, in other implementations, the controller 210 may be coupled to only one or two of the DC-DC voltage converter circuit 208, the power or current limiter circuit 212, and the overcurrent protection circuit 214.

[0044] The controller 210 is configured to operate the power and / or current limiter circuit 212 to limit the DC output power or DC output current of the DC-DC converter 200 below a specified output power threshold or a specified output current threshold. For example, the controller 210 can be configured to control the power or current limiter circuit 212 to limit the DC output power of the DC-DC converter 200 below a specified output power threshold in a range of about 100 W to about 2500 W.

[0045] Alternatively or additionally, the controller 210 may be configured to control the power and / or current limiter circuit 212 to limit the DC output current of the DC-DC converter 200 below a specified output current threshold in the range of about 1 A to about 50 A. In other embodiments, the power and / or current limiter circuit 212 may limit the DC output power or current below a threshold outside of the ranges listed above.

[0046] although Figure 2 A controller 210 is shown coupled to a power and / or current limiter circuit 212 to operate the power and / or current limiter circuit 212. In other embodiments, the power and / or current limiter circuit 212 may be independent of the controller 210 (i.e., not coupled to the controller 210), and the power and / or current limiter circuit 212 may operate without receiving any control signals from the controller 210, etc.

[0047] Controller 210 is configured to control overcurrent protection circuit 214 to protect DC-DC converter 200 from overcurrent conditions. For example, controller 210 can be configured to control overcurrent protection circuit 214 to inhibit the DC output current at bullet terminal 206 from exceeding an overcurrent condition threshold that could damage DC-DC converter 200.

[0048] As an example, the overcurrent protection circuit 214 may limit the DC output current of the DC-DC converter 200 below a threshold in a range of about 1 A to about 50 A. In other implementations, the overcurrent protection circuit 214 may limit the DC output current below a threshold outside of the ranges listed above.

[0049] As described above, in addition to the main overcurrent protection provided by the overcurrent protection circuit 214, the DC-DC converter 200 may also include a backup overcurrent function (e.g., a backup overcurrent protection circuit, a switch, etc.) that creates an air gap between the bullet terminal 204 and the bullet terminal 206 when the main overcurrent protection provided by the overcurrent protection circuit 214 is insufficient to adequately limit the DC output current.

[0050] although Figure 2 A controller 210 is shown coupled to an overcurrent protection circuit 214 to operate the overcurrent protection circuit 214. In other embodiments, the overcurrent protection circuit 214 may be independent of the controller 210 (i.e., not coupled to the controller 210), and the overcurrent protection circuit 214 may operate without receiving any control signal from the controller 210, etc.

[0051] As described herein, the controller 210 may be configured to perform operations using any suitable combination of hardware and software. For example, the controller 210 may include any suitable circuitry, logic gates, microprocessors, computer executable instructions stored in a memory, etc. that are operable to cause the controller 210 to perform the actions described herein (e.g., operate the DC-DC voltage converter circuit 208, etc.).

[0052] In some embodiments, the operating parameters of the DC-DC converter 200 can be adjusted by a user. For example, the user can set one or more voltage values ​​(e.g., voltage input value, voltage output value, voltage conversion value, etc.) of the DC-DC voltage converter circuit 208, the DC output power or current limit threshold of the power and / or current limiter circuit 212, the overcurrent condition threshold of the overcurrent protection circuit 214, etc.

[0053] These values ​​may be set or adjusted prior to operation of the DC-DC converter 200, during operation of the DC-DC converter 200, etc. These values ​​may be set or adjusted manually via inputs on the housing 202 of the DC-DC converter 200, via a computing device coupled to the controller 210 of the DC-DC converter 200 via a wired and / or wireless connection, etc.

[0054] Figure 3 1 shows an example of an alternative housing 302 for a DC-DC converter 300 according to another example embodiment of the present disclosure. Figure 3 As shown, the housing 302 is a bullet-type connector converter housing. The housing 302 includes a pair of bullet-type terminals 304 and 306. Each of the bullet-type terminals 304 and 306 can be one of a bullet-type line terminal, a bullet-type load terminal, or the like.

[0055] The DC-DC converter 300 may be similar to Figure 1 and Figure 2 The DC-DC converters 100 and 200 are shown in FIG. Figure 3 The housing 302 may include Figure 1 and Figure 2 1 and 2. One or more of the DC-DC voltage converter circuits 108 and 208, the power and / or current limiter circuit 212, the overcurrent protection circuit 214, and the controllers 110 and 210 are shown in FIG.

[0056] Housing 302 includes a switch 316 (e.g., a toggle handle, a toggle switch, an on / off switch, an enable / disable switch, etc.). Switch 316 can be used to turn DC-DC converter 300 on and / or off, to reset DC-DC converter 300 if DC-DC converter 300 is tripped due to a fault (e.g., an overcurrent condition, an exceeded power limit condition, etc.), etc.

[0057] For example, DC-DC converter 300 may include one or more fault protection circuits coupled between bullet terminal 304 and bullet terminal 306. In the event that the fault protection circuit detects a fault condition of DC-DC converter 300, experiences a fault condition, etc., the fault protection circuit may disable DC-DC converter 300 (e.g., to disconnect bullet terminal 304 from bullet terminal 306 to create an open circuit).

[0058] The DC-DC converter 300 may include a low voltage disconnect capability. For example, a controller (e.g., Figure 1 The controller 110 of the embodiment of the present invention can be configured to sense, detect, etc., a low voltage condition of the DC-DC converter 300 (e.g., when the DC voltage input or the DC voltage output of the DC-DC converter 300 drops below a low voltage condition threshold). In this case, the controller can disconnect the bullet terminal 304 from the bullet terminal 306 (e.g., by opening the circuit).

[0059] The DC-DC converter 300 may include any suitable current sensor for sensing, detecting, etc. a DC input current or a DC output current of the DC-DC converter 300. Similarly, the DC-DC converter 300 may include any suitable voltage sensor for sensing, detecting, etc. a voltage supplied to the DC-DC converter 300 from an external source (e.g., a remote radio input voltage connected to a sense lead of the DC-DC converter 300, etc.).

[0060] For example, the voltage sensor may sense the DC input voltage or the DC output voltage of the DC-DC converter 300. In these cases, the current sensor or the voltage sensor may be coupled to the controller to provide the sensed current or voltage value to the controller, and the controller may use the sensed value to adjust the DC output voltage of the DC-DC converter 300.

[0061] In some embodiments, the controller of the DC-DC converter 300 (eg, Figure 1 The controller 110 of the embodiment of the present invention can be configured to receive a manual on / off input. For example, the switch 316 can provide a manual on / off input to the controller. In other embodiments, the housing 302 can have an independent switch, button, etc. for manual on / off input.

[0062] In these cases, the controller can be configured to operate the DC-DC converter 300 based on a manual on / off input (e.g., shutting down operation of the device 300 in response to a manual off input, turning on operation of the DC-DC converter 300 in response to a manual on input, etc.).

[0063] In some embodiments, the controller can be configured to receive a remote on / off input to operate the DC-DC converter 300 according to a remote on / off input command, control, etc. For example, the controller can communicate with a remote computing device via a wired connection, a wireless connection (e.g., cellular, WiFi, BLUETOOTH, etc.). The remote computing device can provide an on / off control input to the controller to remotely turn on and off the operation of the DC-DC converter 300.

[0064] As another optional feature, the controller can provide monitoring and / or programming capabilities to another computing device (e.g., a computer, a cell phone, another commercial off-the-shelf (COTS) device, etc.), a display on the DC-DC converter 300 itself, etc. For example, as described above, the controller can communicate with the computing device via a wired connection, a wireless connection, etc. The controller can provide the status of the monitored parameters of the DC-DC converter 300 to the computing device, etc. In some embodiments, the computing device is capable of programming the controller, etc.

[0065] like Figure 3 As shown, housing 302 includes alarm contacts 318. Alarm contacts 318 are shaped to couple with standard alarm contacts (e.g., standard alarm pin locations, etc.) on a power panel, etc., to which DC-DC converter 300 is coupled (i.e., via bullet terminals 304 and 306).

[0066] DC-DC converter 300 may be configured to detect an alarm condition of DC-DC converter 300 (eg, due to a fault condition of DC-DC converter 300 , etc.), and alarm contact 318 may be configured to provide an alarm signal when the alarm condition is detected.

[0067] For example, a controller (e.g. Figure 1 14, etc.) can be coupled to the alarm contact 318 and configured to provide an alarm signal to the alarm contact 318 in response to detecting an alarm condition of the DC-DC converter 300. In some embodiments, the DC-DC converter 300 can have the ability to generate an alarm or not generate an alarm when the switch 316 is in the closed or disabled position.

[0068] Figure 4 An alternative housing 402 of a DC-DC converter 400 is shown according to another example embodiment of the present disclosure. Figure 4 As shown, housing 402 is a toggle handle bullet type joint breaker housing. Figure 3The housing 302 in the embodiment of the present invention includes a pair of bullet terminals 404 and 406. Each of the bullet terminals 404 and 406 can be one of a bullet-type line terminal, a bullet-type load terminal, and the like.

[0069] The DC-DC converter 400 may be similar to Figure 1 and Figure 2 The DC-DC converters 100 and 200 are shown in FIG. Figure 4 The housing 402 may include Figure 1 and 2 1 and 2. One or more of the DC-DC voltage converter circuits 108 and 208, the power and / or current limiter circuit 212, the overcurrent protection circuit 214, and the controllers 110 and 210 are shown in FIG.

[0070] Housing 402 includes a switch 416 (e.g., a toggle handle, a toggle switch, an on / off switch, an enable / disable switch, etc.). Switch 416 can be used to turn DC-DC converter 400 on and / or off, reset DC-DC converter 400 if DC-DC converter 400 is tripped due to a fault (e.g., an overcurrent condition, an exceeded power limit condition, etc.), etc.

[0071] like Figure 4 As shown, housing 402 includes alarm contacts 418 that are shaped to couple with standard alarm contacts on a circuit breaker, power panel, etc. Alarm contacts 418 may be similar to alarm contacts 318 of DC-DC converter 300 described above.

[0072] Figure 5 An alternative housing 502 of a DC-DC converter 500 is shown according to another example embodiment of the present disclosure. Figure 5 As shown, housing 502 is a bullet-type connector fuse holder housing. Figure 3 and Figure 4 The housing 302 and 402 in the embodiment of the present invention, the housing 502 includes two bullet terminals 504 and 506. Each of the bullet terminals 504 and 506 can be one of a bullet-type line terminal, a bullet-type load terminal, and the like.

[0073] The DC-DC converter 500 may be similar to Figure 1 and Figure 2 The DC-DC converters 100 and 200 are shown in FIG. Figure 5 The housing 502 may include Figure 1 and Figure 2 1 and 2. One or more of the DC-DC voltage converter circuits 108 and 208, the power and / or current limiter circuit 212, the overcurrent protection circuit 214, and the controllers 110 and 210 are shown in FIG.

[0074] Housing 502 includes fuse 520. Fuse 520 may be any suitable fuse or the like adapted to trip if DC-DC converter 500 experiences a fault (eg, an over-current condition, an exceed power limit condition, etc.).

[0075] For example, the DC-DC converter 500 may include one or more fault protection circuits coupled between the bullet terminal 504 and the bullet terminal 506. In the event that the fault protection circuit detects a fault condition of the DC-DC converter 500, experiences a fault condition, etc., the fault protection circuit may trip the fuse 520 (e.g., to disconnect the bullet terminal 504 from the bullet terminal 506 to create an open circuit).

[0076] like Figure 5 As shown, the housing 502 includes an alarm contact 518 that is configured to couple with an alarm contact on a circuit breaker, power panel, etc. The alarm contact 518 may be similar to the alarm contacts 318 and 418 described above.

[0077] Housings 302, 402, and 502 may have an integer multiple of the package width available in a bullet-style device pole. In some embodiments, the DC-DC converters described herein may include flying leads to facilitate connection to a return bus to a positive (+) or negative (-) voltage connection point.

[0078] The DC-DC converters described herein may include one or more visual indicators, such as LEDs, to show an over-current condition, an open circuit condition, a device fault condition, etc. The DC-DC converters may be UL listed, may be rated to operate up to 65 degrees Celsius (or higher), may comply with FCC Class B standards, etc.

[0079] According to another example embodiment, a method for converting a DC voltage using a DC-DC converter is disclosed. The DC-DC converter includes a housing having at least two bullet terminals. The at least two bullet terminals are configured to mate with corresponding terminals of a DC bullet breaker panel. The apparatus also includes a DC-DC converter circuit coupled between the at least two bullet terminals, and a controller coupled to the DC-DC converter circuit.

[0080] An example method includes receiving a DC input voltage from one of the corresponding terminals of a DC bullet breaker panel at a first bullet terminal of at least two bullet terminals and converting the received DC input voltage to a different DC output voltage using a DC-DC converter circuit. The method also includes supplying the converted DC output voltage to another of the corresponding terminals of the DC bullet breaker panel via another of the at least two bullet terminals.

[0081] In some embodiments, supplying the converted DC output voltage includes supplying the converted DC output voltage to a wireless radio located on a radio tower. In those cases, receiving the DC input voltage may include receiving the DC input voltage from a battery, and supplying the converted DC output voltage may include supplying the converted DC output voltage to the wireless radio during a utility power outage.

[0082] As described herein, example embodiments may combine the functionality of an overcurrent protection device, a disconnect switch, a DC-DC voltage converter circuit, a power and / or current limiter circuit, and the like in a DC-DC converter package having the form factor of a bullet-type DC breaker to be inserted into a DC bullet-type breaker panel, such that the embodiments described herein may be used in any suitable DC power distribution system incorporating a bullet-type circuit device (e.g., a bullet-type DC breaker), and the like.

[0083] The example DC-DC converters described herein may be used in applications where DC power is delivered to end loads over long distances, among other things. If the DC-DC converter has a DC output voltage that is regulated to a higher level than the DC input voltage, the end loads may be sustained for a longer period of time during battery discharge. The example DC-DC converters described herein may be suitable for meeting Class 2 circuit requirements, among other things.

[0084] In one example, wireless service providers sometimes provide power radio equipment located on radio towers at various heights. Due to the length of the cable loop from the power system to the equipment, the DC voltage at the radio equipment is reduced, and the DC voltage is reduced during the AC interruption (due to battery discharge). Wireless providers can deploy independent DC-DC converter systems connected to existing -48VDC rectifier / battery plants to increase the output voltage to the load to allow the radio to maintain operation during the interruption and reduce the size of the cable that powers the remote load. In addition, distributed antenna system (DAS) providers deploy Class 2 circuit converter systems that keep the power of each circuit within the 100VA limit. The installation of independent converter systems requires considerable additional costs and additional rack space. The example embodiments described herein can allow one or both of these functions to be implemented in the existing power system, thereby reducing the additional costs required and the space required. Existing wiring can be potentially reused, and the labor required to install independent converter plants can be reduced.

[0085] The present disclosure also has the following configurations:

[0086] 1. A DC-DC converter, comprising:

[0087] a housing having at least two bullet terminals configured to mate with corresponding terminals in a DC bullet breaker panel;

[0088] a DC-DC voltage converter circuit coupled between the at least two bullet terminals; and

[0089] A controller is coupled to the DC-DC voltage converter circuit, the controller being configured to control the DC-DC voltage converter circuit to convert a DC input voltage at a first bullet terminal of the at least two bullet terminals into a different DC output voltage at another bullet terminal of the at least two bullet terminals.

[0090] 2. The DC-DC converter according to Option 1 further includes: a power or current limiter circuit coupled between the at least two bullet-type terminals, wherein the power or current limiter circuit is configured to limit the DC output power or DC output current of the DC-DC converter to below a specified output power threshold or a specified output current threshold.

[0091] 3. The DC-DC converter according to Option 1 or 2 further includes: an overcurrent protection circuit coupled between the at least two bullet terminals, the overcurrent protection circuit being configured to protect the DC-DC converter from an overcurrent condition.

[0092] 4. The DC-DC converter according to claim 3, wherein:

[0093] The controller is coupled to the power or current limiter circuit, and the controller is configured to control the power or current limiter circuit to limit the DC output power or DC output current of the DC-DC converter below a specified output power threshold or a specified output current threshold; or

[0094] The controller is coupled to the overcurrent protection circuit, and the controller is configured to control the overcurrent protection circuit to protect the DC-DC converter from an overcurrent condition.

[0095] 5. The DC-DC converter according to any preceding solution, wherein the controller is configured to operate the DC-DC voltage converter circuit to convert a DC input voltage within a specified voltage input range into a DC output voltage within a specified voltage output range.

[0096] 6. The DC-DC converter of claim 5, wherein the specified voltage input range is approximately -42 VDC to -58 VDC.

[0097] 7. A DC-DC converter according to claim 5 or 6, wherein the specified voltage output range is approximately -48V to -72VDC.

[0098] 8. A DC-DC converter according to any one of options 2 to 7, wherein the power or current limiter circuit is configured to limit the DC output power to below a specified output power threshold in the range between 100W and 2500W.

[0099] 9. A DC-DC converter according to any one of options 2 to 8, wherein the power or current limiter circuit is configured to limit the DC output current to below a specified output current threshold in the range between 1A and 50A.

[0100] 10. A DC-DC converter according to any one of options 2 to 9, wherein the overcurrent protection circuit is configured to protect the DC-DC converter from an overcurrent condition at a DC output current threshold in a range between 1A and 50A.

[0101] 11. A DC-DC converter according to any preceding solution, wherein the at least two bullet terminals comprise bullet-type line terminals or bullet-type load terminals.

[0102] 12. A DC-DC converter according to any preceding aspect, wherein the housing has substantially the same form factor as a bullet-style DC breaker.

[0103] 13. A DC-DC converter according to any preceding solution, further comprising:

[0104] a current sensor coupled to detect a DC input current or a DC output current of the DC-DC converter; or

[0105] A voltage sensor is coupled to detect a DC input voltage of the DC-DC converter, a DC output voltage of the DC-DC converter, or a voltage on an input terminal of a remote radio unit for controlling the DC output voltage of the DC-DC converter.

[0106] 14. The DC-DC converter according to any preceding solution, further comprising a fault protection circuit coupled between the at least two bullet terminals.

[0107] 15. The DC-DC converter according to any preceding aspect, wherein the controller is configured to receive a remote on / off input to control the DC-DC converter via a remote on / off operation control.

[0108] 16. The DC-DC converter of any preceding aspect, further comprising an alarm contact positioned on an exterior of the housing, the alarm contact being configured to send an alarm signal upon detecting an alarm condition of the DC-DC converter.

[0109] 17. A DC power distribution system, comprising a DC-DC converter according to any one of Schemes 1 to 16, and further comprising a DC bullet-type circuit breaker panel having at least two bullet-type terminals, wherein the at least two bullet-type terminals of the DC-DC converter are coupled to the at least two bullet-type terminals of the DC bullet-type circuit breaker panel.

[0110] 18. A method of converting a DC voltage using a DC-DC converter, the DC-DC converter comprising a housing having at least two bullet terminals, a DC-DC voltage converter circuit coupled between the at least two bullet terminals, and a controller coupled to the DC-DC voltage converter circuit, the at least two bullet terminals being configured to mate with corresponding terminals in a DC bullet breaker panel, the method comprising:

[0111] receiving a DC input voltage from one of the corresponding terminals of the DC bullet breaker panel at a first of the at least two bullet terminals;

[0112] converting the received DC input voltage into a different DC output voltage by the DC-DC voltage converter circuit; and

[0113] The converted DC output voltage is supplied to another one of the corresponding terminals of the DC bullet breaker panel via another one of the at least two bullet terminals.

[0114] 19. The method of claim 18, wherein supplying the converted DC output voltage comprises supplying the converted DC output voltage to a wireless radio device located on a radio tower.

[0115] 20. The method according to claim 19, wherein:

[0116] Receiving the DC input voltage includes: receiving the DC input voltage from a battery; and

[0117] Supplying the converted DC output voltage includes supplying the converted DC output voltage to the wireless radio during a utility power outage.

[0118] 21. A DC-DC converter according to any one of embodiments 1 to 17, wherein the controller is configured to communicate with a computing device so that the computing device can monitor or program the DC-DC converter.

[0119] 22. The DC-DC converter according to any one of schemes 1 to 17 and 21, wherein the controller is configured to receive a manual on / off input to control the DC-DC converter via a manual on / off operation control.

[0120] 23. A DC-DC converter according to any one of embodiments 1 to 17 and 21 to 22, wherein the controller is configured to disconnect at least one of the bullet terminals when a low voltage condition is detected.

[0121] Example embodiments and aspects of the present disclosure may provide any one or more (or none) of the following advantages: a DC-DC converter interchangeable with a bullet-type DC breaker having bullet-type terminals, a combination of multiple DC-DC converter functions and features into a compact device, a device that can be used with equipment from multiple vendors, operability without the need to change or modify existing equipment, communication with smart phones, etc.

[0122] The foregoing description of the embodiments has been provided for the purpose of illustration and description. It is not intended to be exhaustive or limit the present disclosure. Each element or feature of a particular embodiment is generally not limited to the particular embodiment, but is interchangeable and can be used in a selected embodiment where applicable, even if not specifically shown or described. These elements or features can also be changed in a variety of ways. Such changes should not be considered as departing from the present disclosure, and all these modifications are intended to be included in the scope of the present disclosure.

Claims

1. A DC-DC converter, comprising: a housing having at least two bullet terminals configured to mate with corresponding terminals in a DC bullet breaker panel into which the DC-DC converter is inserted via the at least two bullet terminals, the at least two bullet terminals comprising paired bullet terminals; a DC-DC voltage converter circuit coupled between the at least two bullet terminals; a controller coupled to the DC-DC voltage converter circuit, the controller being configured to control the DC-DC voltage converter circuit to convert a DC input voltage at a first bullet terminal of the pair of bullet terminals to a different DC output voltage at the other bullet terminal of the pair of bullet terminals; an overcurrent protection circuit coupled between the at least two bullet terminals, the overcurrent protection circuit configured to protect the DC-DC converter from an overcurrent condition; a fault protection circuit coupled between the pair of bullet terminals to disconnect the at least two bullet terminals to create an open circuit when a fault condition of the DC-DC converter is detected; a power and current limiter circuit coupled between the DC-DC voltage converter circuit and the overcurrent protection circuit, the power and current limiter circuit being configured to limit a DC output power of the DC-DC converter below a specified output power threshold and to limit a DC output current of the DC-DC converter below a specified output current threshold, the power and current limiter circuit comprising a power and current limiting circuit topology; and A backup overcurrent protection circuit creates a physical disconnect between the at least two bullet terminals in the event that the overcurrent protection provided by the overcurrent protection circuit is insufficient to adequately limit the DC output current.

2. The DC-DC converter according to claim 1, wherein: The controller is coupled to the power and current limiter circuit, and the controller is configured to control the power and current limiter circuit to limit the DC output power and DC output current of the DC-DC converter to below a specified output power threshold and a specified output current threshold, respectively; or The controller is coupled to the overcurrent protection circuit, and the controller is configured to control the overcurrent protection circuit to protect the DC-DC converter from an overcurrent condition.

3. The DC-DC converter according to claim 1, wherein: The controller is configured to operate the DC-DC voltage converter circuit to convert a DC input voltage within a specified voltage input range to a DC output voltage within a specified voltage output range.

4. The DC-DC converter according to claim 3, wherein: The specified voltage input range is -42 VDC to -58 VDC.

5. The DC-DC converter according to claim 3, wherein: The specified voltage output range is -48V to -72VDC.

6. The DC-DC converter according to claim 1, wherein: The power and current limiter circuit is configured to limit the DC output power below a specified output power threshold in a range between 100W and 2500W.

7. The DC-DC converter according to claim 1, wherein: The power and current limiter circuit is configured to limit the DC output current below a specified output current threshold in a range between 1A and 50A.

8. The DC-DC converter according to claim 1, wherein: The overcurrent protection circuit is configured to protect the DC-DC converter from an overcurrent condition at a DC output current threshold in a range between 1A to 50A.

9. The DC-DC converter according to claim 1, wherein: The at least two bullet terminals include bullet-type line terminals or bullet-type load terminals.

10. The DC-DC converter according to claim 1, wherein: The housing has the same form factor as a bullet-style DC breaker.

11. The DC-DC converter according to claim 1, further comprising: a current sensor coupled to detect a DC input current or a DC output current of the DC-DC converter; or A voltage sensor is coupled to detect a DC input voltage of the DC-DC converter, a DC output voltage of the DC-DC converter, or a voltage on an input terminal of a remote radio unit for controlling the DC output voltage of the DC-DC converter.

12. The DC-DC converter according to claim 1, wherein: The controller is configured to receive a remote on / off input to control the DC-DC converter via a remote on / off operational control.

13. The DC-DC converter of claim 1, further comprising an alarm contact positioned on an exterior of the housing, the alarm contact configured to send an alarm signal upon detecting an alarm condition of the DC-DC converter.

14. The DC-DC converter according to claim 1, wherein: The controller is configured to communicate with a computing device to enable the computing device to monitor or program the DC-DC converter.

15. The DC-DC converter according to claim 1, wherein: The controller is configured to receive a manual on / off input to control the DC-DC converter via a manual on / off operation control.

16. The DC-DC converter according to claim 1, wherein: The controller is configured to disconnect at least one of the bullet terminals upon detecting a low voltage condition.

17. A DC power distribution system, comprising a DC-DC converter according to any one of claims 1 to 16, and further comprising a DC bullet-type circuit breaker panel having at least two bullet-type terminals, wherein: The at least two bullet terminals of the DC-DC converter are coupled to the at least two bullet terminals of the DC bullet breaker panel.

18. A method of converting a DC voltage using a DC-DC converter, the DC-DC converter comprising a housing having at least two bullet terminals, a DC-DC voltage converter circuit coupled between the at least two bullet terminals, a power and current limiter circuit coupled between the DC-DC voltage converter circuit and an overcurrent protection circuit, and a controller coupled to the DC-DC voltage converter circuit, the at least two bullet terminals being configured to mate with corresponding terminals in a DC bullet breaker panel, and the at least two bullet terminals comprising paired bullet terminals, the method comprising: receiving a DC input voltage from one of the corresponding terminals of the DC bullet breaker panel at a first bullet terminal of the pair of bullet terminals; converting the received DC input voltage into a different DC output voltage by the DC-DC voltage converter circuit; supplying the converted DC output voltage to the other of the corresponding terminals of the DC bullet breaker panel via a second bullet terminal of the pair of bullet terminals; limiting a DC output power supplied by the DC-DC converter at the second bullet terminal to below a specified output power threshold and limiting a DC output current supplied by the DC-DC converter at the second bullet terminal to below a specified output current threshold by the power and current limiter circuit, the power and current limiter circuit comprising a power and current limiting circuit topology; upon detecting a fault condition of the DC-DC converter circuit, disconnecting the at least two bullet terminals to create an open circuit via a fault protection circuit coupled between the pair of bullet terminals; as well as controlling the overcurrent protection circuit to protect the DC-DC converter from an overcurrent condition, Wherein, in the event that the overcurrent protection provided by the overcurrent protection circuit is insufficient to adequately limit the DC output current, a physical disconnection is created between the at least two bullet terminals by a backup overcurrent protection circuit.

19. The method according to claim 18, wherein: Supplying the converted DC output voltage includes supplying the converted DC output voltage to a wireless radio device located on a radio tower.

20. The method of claim 19, wherein: Receiving the DC input voltage includes: receiving the DC input voltage from a battery; and Supplying the converted DC output voltage includes supplying the converted DC output voltage to the wireless radio during a utility power outage.

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