Selective activation of branches in power converter

Abstract

Systems and methods for selectively activating branches of a converter are presented. The system may include a power converter including a plurality of branches for converting power delivered between a power source and a load. The system may include a controller configured to couple with the power converter. The controller may identify parameters defining operating conditions of the power converter. The controller may determine a number of branches of the power converter to be used based on the parameters. The controller may identify a metric indicative of utilization of each of the plurality of branches. The controller may activate a subset of at least one leg of the plurality of legs according to the number of legs and the metric to deliver power between the power source and the load.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit and priority of U.S. patent application No. US18 / 812824, filed on August 22, 2024, which claims the benefit and priority of U.S. provisional patent application No. US63 / 540870, filed on September 27, 2023, entitled "Selective Activation of Branches in a Power Converter," and the entire contents of these applications are incorporated herein by reference. Technical Field

[0002] The present disclosure relates to power systems and more particularly to systems and methods for selectively activating branches of a power converter. Background Art

[0003] Converters convert electricity from one voltage level to another. Converters facilitate the transfer of electricity between two electrical components. Repeated use of converters can cause degradation of the converter's internal components, eventually leading to failure and inoperability. Summary of the invention

[0004] At least one aspect of the present disclosure relates to a system for selectively activating branches of a converter. The system may include a power converter, the power converter including multiple branches for converting power transmitted between a power source and a load. The system may include a controller configured to be coupled to the power converter. The controller may have one or more processors coupled to a memory. The controller may identify parameters that define operating conditions of the power converter. The controller may determine the number of branches of the power converter to be used based on the parameters. The controller may identify a metric indicating the utilization of each branch in a plurality of branches. The controller may activate at least a subset of the multiple branches based on the number of branches and the metric, so that the at least subset of the branches transmits power between the power source and the load.

[0005] In some embodiments, the controller may monitor a change in a parameter defining the power delivered by the subset of the branches of the power converter. In some embodiments, the controller may, in response to detecting the change, re-determine the number of branches of the plurality of branches for delivering power between the power source and the load based on the parameter. In some embodiments, the controller may monitor the time elapsed since activating at least a subset of the branches to deliver power. In some embodiments, the controller may determine to reselect at least a subset of the branches from the plurality of branches in response to the elapsed time exceeding a threshold.

[0006] In some embodiments, the controller may determine that the number of the branches of the power converter to be used is less than the total number of branches available for use. In some embodiments, the controller may identify at least one second branch from the plurality of branches corresponding to the number of branches of the power converter to be used; in some embodiments, the controller may select the subset of branches from the subset of the plurality of branches based on the number of branches and a metric indicating the utilization of each branch of the at least one second branch.

[0007] In some embodiments, the controller may determine that the number of branches of the power converter to be used is less than the total number of branches available for use. In some embodiments, in response to determining that the number of branches to be used is less than the total number of branches, the controller may identify a plurality of metrics for a corresponding subset of the plurality of branches in the plurality of branches. Each of the plurality of metrics may correspond to a respective utilization of a corresponding subset of the plurality of branches in the subset of the plurality of branches. In some embodiments, the controller may select at least a subset of branches from the subset of the plurality of branches based on the plurality of metrics.

[0008] In some embodiments, the controller may determine that the number of branches of the power converter to be used is equal to the total number of branches available for use. In some embodiments, the controller may select the plurality of branches for activation in response to determining that the number of branches to be used is equal to the total number. In some embodiments, the parameter includes at least one of a duty cycle or a power command, and wherein the metric identifies at least one of a total utilization or a remaining life.

[0009] At least one other aspect of the present disclosure relates to a method for controlling a power converter. The method may include identifying, by a controller, parameters defining an operating condition of the power converter; determining, by the controller, a number of branches of the power converter to be used based on the parameters; identifying, by the controller, a metric indicating a utilization of each of the plurality of branches; and activating, by the controller, at least one of the plurality of branches based on the number of branches and the metric, so that the at least one branch transmits power between a power source and a load.

[0010] In some embodiments, the method may include monitoring, by the controller, a change in a parameter defining the power delivered through at least one branch of the power converter; and in response to detecting the change, re-determining, by the controller, the number of branches to be used based on the parameter. In some embodiments, the method may include monitoring, by the controller, a time elapsed since the at least one branch was activated to deliver power; and in response to the elapsed time exceeding a threshold, determining, by the controller, to reselect at least one branch from a plurality of branches.

[0011] In some embodiments, the method may include determining, by the controller, that the number of branches of the power converter to be used is less than the total number of branches available for use; identifying, by the controller, at least one second branch from the plurality of branches corresponding to the number of branches of the power converter to be used; and selecting, by the controller, at least one branch from the at least one second branch of the branches based on the number of branches and a metric indicating utilization of the at least one second branch.

[0012] In some embodiments, the method may include determining, by the controller, that the number of branches of the power converter to be used is less than the total number of branches available for use; in response to determining that the number of the branches to be used is less than the total number of branches, identifying, by the controller, a plurality of metrics of a corresponding subset of the plurality of branches among the plurality of branches, each of the plurality of metrics corresponding to a respective utilization rate of a corresponding subset of the subset of the plurality of branches; and selecting, by the controller, the subset of branches from the subset of the plurality of branches based on the plurality of metrics.

[0013] In some embodiments, the method includes determining, by a controller, that the number of branches of the power converter to be used is equal to the total number of branches available for use; and in response to determining that the number of branches to be used is equal to the total number, selecting, by the controller, the plurality of branches for activation. In some embodiments, the parameter includes at least one of a duty cycle or a power command, and the metric identifies at least one of a total utilization or a remaining life.

[0014] At least one other aspect of the present disclosure relates to an apparatus for controlling a power converter. The apparatus may include one or more processors coupled to a memory. The one or more processors may: identify parameters defining operating conditions of a power converter; determine the number of branches of the power converter to be used based on the parameters; identify a metric indicating utilization of each of a plurality of branches; and activate a subset of the branches of the plurality of branches based on the number of branches and the metric, so that the subset of branches transmits power between the power source and the load.

[0015] In some embodiments, one or more processors may monitor a change in a parameter defining the power delivered by the subset of branches of the power converter; and in response to the detected change, re-determine the number of branches to be used based on the parameter. In some embodiments, one or more processors may monitor the time elapsed since the subset of branches was activated to deliver power; and in response to the elapsed time exceeding a threshold, determine to reselect a subset of branches from the plurality of branches. In some embodiments, the parameter includes at least one of a duty cycle or a power command, and the metric identifies at least one of a total utilization or a remaining life.

[0016] From the following detailed description in conjunction with the accompanying drawings, these and other features and the organization and mode of their operation will become apparent. Many specific details are provided in order to thoroughly understand the embodiments of the disclosed subject matter. The described features of the disclosed subject matter can be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the present invention can be combined with one or more features of different aspects of the present invention. In addition, in certain embodiments and / or implementations, it can be recognized that additional features that may not all exist in all embodiments or implementations. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements unless otherwise specified, and in which:

[0018] Figure 1 shows a block diagram of a system for delivering power between a power source and a load in accordance with an illustrative embodiment;

[0019] Figure 2 A flow chart showing a method of selectively activating one or more branches of a power converter according to an illustrative embodiment;

[0020] Figure 3 A graph showing power converter input current ripple for different numbers of branches of a power converter for different duty cycles according to an illustrative embodiment;

[0021] Figure 4 a graph showing converter efficiency versus the number of different branches of the power converter activated for a given input power in accordance with an illustrative embodiment; and

[0022] Figures 5A to 5E A flow chart is shown of a method of determining the number of branches of a power converter under various conditions and selectively activating the determined number of branches in accordance with an illustrative embodiment. DETAILED DESCRIPTION

[0023] The following is a more detailed description of various concepts related to methods, devices, apparatuses, and systems for selectively activating branches of a converter and their implementations. As a power converter is used, the various components of the converter (e.g., branches and constituent components of the converter) may degrade over time, ultimately leading to failure. By selectively activating one or more branches of a power converter, the performance and overall life of the power converter and its various branches can be enhanced and improved. The various concepts introduced above and discussed in more detail below can be implemented in any number of ways, as the concepts described are not limited to any particular implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0024] Now refer to Figure 1 , depicts a block diagram of a system 100 for delivering power between a power source and a load according to an example embodiment. In general, the system may include, among other things, at least one power subsystem 105, at least one power source 110, and at least one load 115. The power subsystem 105 may include, among other things, at least one power converter 120, at least one controller 125, and at least one system controller 160. The power converter 120 (sometimes collectively referred to herein as a converter) may include, among other things, a set of branches 135A-N (hereinafter collectively referred to as branches 135). The controller 125 may include, among other things, at least one sensor 130, at least one processor 140, and at least one memory 145. The memory 145 may store or include computer-readable instructions corresponding to, among other things, at least one utilization meter 150 and at least one branch manager 155, for execution by the processor 140.

[0025] The components of the power subsystem 105 (e.g., the controller 125 and the system controller 160) may be implemented using circuitry, such as a processor 140 and a memory 145 for the controller 125. The circuitry may include logic or machine-readable instructions (e.g., in the utilization meter 150 and the branch manager 155 embodied on the memory 145) to define the behavior, functionality, and operation of the controller 125. The functionality imparted or defined by the machine-readable instructions (e.g., as described herein with respect to the utilization meter 150 and the branch manager 155) may be attributed to the controller 125 as a whole. The circuitry may be implemented by a computer-readable medium, which may include code written in any programming language including, but not limited to, Java, JavaScript, Python, and any conventional procedural programming language (e.g., the "C" programming language or similar programming languages). The machine-readable instructions may be stored and maintained on the memory. The circuitry may include one or more processors to execute the machine-readable instructions. The one or more processors may be coupled to the memory to execute the machine-readable instructions therefrom.

[0026] Processor 140 may be implemented as a single-chip or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, that is intended to perform the functions described herein. The processor may be a microprocessor, or any conventional processor or state machine. Processor 140 may also be implemented as a combination of computing devices, such as a combination of a digital signal processor (DSP) and a microprocessor, a plurality of microprocessors, one or more microprocessors combined with a DSP core, or any other such configuration. In some embodiments, one or more processors may be shared by a plurality of circuits that may include or otherwise share the same processor, which in some example embodiments may execute instructions stored or otherwise accessed via different regions of a memory. Alternatively or additionally, one or more processors may be configured to perform or otherwise perform certain operations independently of one or more coprocessors. In other example embodiments, two or more processors may be connected via a bus to implement independent, parallel, pipelined, or multithreaded instruction execution.

[0027] The memory (e.g., memory 145) (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or computer code to complete or facilitate the various processes, layers, and modules described in the present disclosure. The memory may be communicatively connected to the processor to provide computer code or instructions to the processor to perform at least some of the processes described herein. In addition, the memory may be or include tangible, non-transient volatile memory or non-volatile memory. Thus, the memory may include a database component, an object code component, a script component, or any other type of information structure for supporting the various activities and information structures described herein.

[0028] In some embodiments, the processor in the power subsystem 105 can communicate with one or more remote processors. For example, the utilization meter 150 can be stored on a remote memory and executed on a remote processor to transmit data to a branch manager 155 on the power subsystem 105. The remote processors can be connected to each other via any type of network (e.g., CAN bus, etc.). The memory (e.g., RAM, ROM, flash memory, hard disk storage, etc.) can be a computer-readable medium for storing data or computer code for facilitating the various processes described herein. The memory can be communicatively connected to the processing circuit to provide computer code or instructions for performing at least some of the processes described herein. The memory can be or include tangible, non-transitory volatile memory or non-volatile memory, and can include a database component, an object code component, a script component, or any other type of information structure for supporting the various activities and information structures described herein.

[0029] In more detail, the power supply 110 can generate, output and / or provide electricity. The power supply 110 may include or correspond to any source of electricity (e.g., in direct current (DC) form). The power supply 110 may include, for example, one or more batteries, such as a battery pack (e.g., a collection of batteries for storing charge), a fuel cell, a generator set (e.g., a generator with an engine to generate electricity), a microgrid (e.g., a local system that operates independently or in conjunction with a power grid), a renewable fuel source (e.g., a photovoltaic array, a generator coupled to a hydroelectric turbine, or a wind turbine), a modular reactor (e.g., a nuclear reactor that converts nuclear fuel into energy), a power station (e.g., a facility that generates electricity), or a power interface coupled to an external power supply component, etc. The power supply 110 may be configured to be electrically coupled to the power subsystem 105 (e.g., via a bus or connector). When the power delivered by the power supply 110 is in alternating current (AC) form (e.g., a generator set or a hydroelectric turbine), the power supply 110 and the power subsystem 105 may be configured to be electrically coupled via an AC-DC converter. Power source 110 may be electrically coupled to power subsystem 105 to transmit, send, transfer, or otherwise deliver power through power subsystem 104 .

[0030] The power provided by the power source 110 to the power subsystem 105 (or another electrically coupled component) is direct current (DC) power. For example, the power source 110 may also be a wind turbine to generate DC power for the power subsystem 105. In some embodiments, the power source 110 may be part of the same device, equipment, or component as the power subsystem 105. In some embodiments, the power source 110 may be separate from the power subsystem 105. For example, the power subsystem 105 may be physically separated from the power source 110 and electrically coupled to the power source 110 via an electrical bus connection.

[0031] The power subsystem 105 is configured to couple with the power source 110 and the load 115. The power subsystem 105 can deliver or transfer power between the power source 110 and the load 115. When the power source 110 is discharging to the load 115, the subsystem 105 can accept, harvest, or otherwise receive power drawn from the power source 110. Conversely, when charging from one of the components (e.g., by facing one side of the load 115), the power subsystem 105 can accept, harvest, or otherwise receive power from an external source for charging a power storage device or component (e.g., a battery on one side of the power source 110).

[0032] In the power subsystem 105, the power converter 120 can transform or convert the power to be transmitted between the power source 110 and the load 115. The conversion of power is the conversion of direct current (DC) to DC voltage. The power converter 120 may include one or more components for performing the conversion, such as components such as transistors, diodes, switches, resistors, inductors, and conductors, which are arranged according to the architecture of the type of conversion to be performed. For example, for DC-DC conversion, the power converter 120 can be: a buck converter, a boost converter, a buck-boost converter, a split-pi converter, a forward converter, or a Cuckoo converter. Converter, etc. In some embodiments, the conversion may be unidirectional (eg, power delivered from power source 110 to load 115), bidirectional (eg, power delivered between power source 110 and load 115), etc.

[0033] In the power converter 120, the group of branches 135 may correspond to the components of the power. The group of branches 135 may be electrically coupled to the power source 110 and the load 115. In one embodiment, the group of branches 135 may be electrically coupled in parallel with each other relative to the power source 110 and the load 115. Each branch 135 may correspond to or include a corresponding input terminal coupled to the power source 110 to receive power and a corresponding output terminal coupled to the load 115 to deliver power. The input and output terminals may each include a body, a port, or a conductive component to transmit power between the power source 110 and the load 115.

[0034] Each branch 135 may include one or more components to perform a conversion (e.g., DC to DC voltage conversion) between the input and output terminals. The components of the branch 135 for performing the conversion may include components such as transistors, diodes, inductors, and conductors, which are arranged according to the architecture of the type of conversion to be performed. For example, for DC-DC conversion, each branch 135 may include a buck converter, a boost converter, a buck-boost converter, a split-pi converter, a forward converter, or a Cuckoo converter. Component arrangement of a converter, etc. Each branch 135 can have an active state (e.g., when the switch is connected) and an inactive state (e.g., when the switch is disconnected or not connected), in which the branch 135 is enabled to perform conversion, and in which the branch 135 is disabled and does not perform conversion. Individual activation and deactivation of the group of branches 135 of the power converter 120 can be set and changed by the controller 125.

[0035] The controller 125 may regulate, manage, or otherwise control the voltage and / or current of the power delivered through the power subsystem 105. In some embodiments, the controller 125 is configured to couple with the power source 110 and the power converter 120 to transfer or deliver power between the power source 110 and the power converter 120. In some embodiments, as shown, the controller 125 may be part of the power subsystem 105. The controller 125 may activate or deactivate any branch 135 to start or stop transmitting power.

[0036] The system controller 160 may regulate, process, or otherwise manage the operation of components in the power subsystem 105, including the controller 125. In some embodiments, the system controller 160 may be communicatively coupled to the power subsystem 105 (e.g., the controller 125) via a wireless network or a wired connection. In some embodiments, the system controller 160 may be configured to couple to the power subsystem 105 or the controller 125 therein. In managing operations within the power subsystem 105, the system controller 160 may transmit, send, or otherwise provide one or more parameters that define operating conditions of the power converter 120. These parameters may be provided in the form of messages over the network or may be relayed over a wired connection.

[0037] The controller 125 may receive, retrieve, or otherwise identify one or more parameters from the system controller 160. The parameters identified by the controller 125 may identify or include, for example, a power command (or current command) for the power converter 120. The controller 125 may use the parameters from the system controller 160 to calculate or determine at least one duty cycle (or duty ratio) of the power converter 120. The power command may correspond to a signal specifying a target output power of the power converter 120. The duty cycle may correspond to the ratio of the portion of the power signal (e.g., a pulse width modulation (PWM) signal) that is on or at a high level to the remaining portion of the signal that is off or at a low level in a cycle. The duty cycle may be determined by the controller 125 as a ratio or the input and output voltages measured by the sensor 130. The duty cycle may be calculated or determined by the controller 125 to achieve a target output defined by the power command (or current command) specified by the system controller 160. In some embodiments, the sensor 130 may sample the input and output voltages so that the controller calculates the duty cycle at defined time intervals (e.g., 1 millisecond). With this identification, the sensor 130 may communicate, send, or otherwise provide a parameter (eg, a duty cycle or power command) to the controller 125 .

[0038] The utilization meter 150 can measure, determine, or otherwise identify at least one usage metric of at least one branch 135 of the power converter 120. The usage metric indicates or provides an indication of the usage of the corresponding branch 135 in the power converter 120. Thus, the usage metric can identify, for example, the total usage duration of the branch 135 since installation or another starting point, the total remaining useful life (RUL) of the branch 135, etc. In one embodiment, the usage metric can be defined in terms of years, days, hours, minutes, seconds, or other time units. In another embodiment, the usage metric can be defined in other forms of units (e.g., a percentage of a total on-time amount specified before the proposed service, etc.).

[0039] For identification, the utilization meter 150 may track a history log of the use of each branch 135 of the power converter 120. The history log may identify the time (e.g., date and time stamp) that a given branch 135 in the power converter 120 was in an active or on state. The history log may be saved on a memory accessible to the controller 125, such as an onboard memory (e.g., memory 145), a remote data or database on a cloud computing system that is communicatively coupled to the controller 125, or the like. Based on the history log, the utilization meter 150 may determine a usage metric for the branch 135. For example, the utilization meter 150 calculates or determines the total or sum of the times identified in the history of a given branch 135 to determine the total duration of use of the branch 135. In some embodiments, the utilization meter 150 may use the history log of a given branch 135 to determine the cumulative time that each branch 135 has been operated as a usage metric. In some embodiments, the utilization meter 150 may monitor, determine, or otherwise identify the amount of time that has passed since the activation of a previously selected branch 135. The amount of time that has passed may be used as one of the usage metrics for the branch 135.

[0040] In some embodiments, the utilization meter 150 can determine a usage metric for each branch 135 based on the number of switching events, the current switched, and the average temperature for a given branch 135. The number of switching events, the current switched, and the average temperature can be extracted or identified from the historical log. For example, the utilization meter 150 can calculate that the branch 135 has a life consumption of 0.01% based on data indicating that the branch 135 has been switched 10 billion times at a current of 100A at a temperature of 120°C. In some embodiments, the utilization meter 150 can determine or identify which branches 135 have been previously used from the historical log. The previously used branch 135 may have been activated during a previous (e.g., recent) power transfer between the power source 110 and the load 115 through the power converter 120.

[0041] In some embodiments, the utilization meter 150 may determine the usage metric based on measurements during normal operation or reliability testing. For example, the gate voltage threshold of the switch in the branch 135 may be measured to determine the remaining life of the switch through a mapping process (e.g., a lookup table). In some embodiments, the utilization meter 150 may determine or identify whether one or more branches 135 are operating normally or faulty based on the results of the reliability test. During normal operation, the controller 125 may identify or determine whether one or more branches 135 are faulty. When it is determined that a given branch 135 is faulty, the branch manager 155 may exclude the branch 135 from the activation selection. When it is determined that a given branch 135 is operating normally, the branch manager 155 may maintain or include the branch 135 as a set of candidate branches 135 for selection for activation.

[0042] The branch manager 155 may calculate, identify, or otherwise determine the number of branches 135 to use based on at least one parameter defining an operating condition. The determination may be based on a function of the parameter to reduce or minimize current ripple in the power (e.g., instantaneous or other undesirable changes in the direct current (DC) output), or to enhance or improve the efficiency of the power converter 120. The function may define or specify a correspondence between a parameter of the operating condition (e.g., a duty cycle or power command, or a combination thereof) and the number of branches 135 to use. The function may be defined specifically for a power converter 120 having a given number of branches 135 using previous reliability or usage measurements. The correspondence defined by the function may be to minimize current ripple, optimize expected service life, or improve the efficiency of the power converter 120. Examples of functions and correspondences may be described below. Figure 3 and Figure 4 Using the definition of this function, the branch manager 155 can identify the number of branches 135 corresponding to the power parameter.

[0043] In some embodiments, the branch manager 155 may compare the number of branches 135 used to implement the parameter with the number of candidate branches 135 for selection. If the number of branches 135 is greater than or equal to the number of available candidate branches 135, the branch manager 155 may allocate or set the number of branches 135 to be used to the number of candidate branches 135. The branch manager 155 may also select all available candidate branches 135 identified as functioning properly for activation. On the other hand, if the number of branches 135 is less than the number of available candidate branches 135, the branch manager 155 may maintain the number of branches 135 to be used. The branch manager 155 may select from the set of candidate branches 135 for activation.

[0044] Based on the number of branches 135 to be used and the usage metric of each branch 135, the branch manager 155 may identify or otherwise select at least a subset of the branches 135 for activation to deliver power between the power source 110 and the load 115. The subset of branches 135 may correspond to (e.g., equal to) the number of branches 135 to be used determined based on a parameter defining an operating condition (e.g., a duty cycle or a power command). The selection of which branches 135 to be activated may depend on the number of branches 135 to be used. When the number of branches to be used is 1, the branch manager 155 may select a branch 135 that is identified as previously unused (e.g., during a recent delivery of power through the power converter 120). In some embodiments, the branch manager 155 may select a branch 135 from the set of branches 135 of the power converter 120 based on the usage metric. For example, the branch manager 155 may select a branch 135 with the lowest total utilization time or the highest remaining useful life.

[0045] In some embodiments, the branch manager 155 may identify or determine whether the number of branches to be used (determined according to the parameter) is less than the total number of branches 135 available for use. The total number of branches 135 may correspond to the number of branches 135 available or operable in the power converter 120. For example, the power converter 120 may have a total of four branches 135A-135D, of which three branches 135A, 135B, and 135D are operable and can be used to deliver power from the power source 110 to the load 115. When the number of branches is equal to the total number of branches 135 available in the power converter 120, the branch manager 155 may select all branches 135 in the power converter 120 for activation. When the number of branches to be used is between 1 and the total number of branches 135 in the power converter 120, the branch manager 155 may identify or select a predefined subset of branches 135. The predefined subset of branches 135 may be determined to obtain better thermal performance. For example, the predefined subset with two branches may include branches 135A and 135D at the first and fourth positions in power converter 120. Since branches 135A and 135D are relatively far from each other, the thermal coupling between them is small, which may result in a lower temperature rise. The predefined subset may also be determined based on factors other than the position of branch 135.

[0046] In some embodiments, the branch manager 155 may identify or select a subset from the predefined subset of branches 135 that corresponds to the number of branches 135 to be used determined from the power converter 120. For example, when two branches are to be used, the branch manager 155 may identify pairs of branches 135, and when three branches are to be used, the branch manager 155 may identify candidate groups of three branches 135, and so on. From the predefined subset, the branch manager 155 may select a subset of branches 135 based on a combination of the respective usage metrics of the respective branches 135. In some embodiments, the branch manager 155 may calculate, identify, or otherwise determine a set of metrics for the predefined subset of branches 135. For each candidate subset of branches 135, the branch manager 155 may determine a corresponding metric corresponding to the utilization of the candidate subset of branches 135. For example, the branch manager 155 can determine the total utilization time or total remaining life of each predefined subset of the branches 135 based on the sum of the individual total utilization time or total remaining life of the branches 135 in the corresponding subset. Through this determination, the branch manager 155 can select the subset of branches 135 with the lowest total utilization time or the highest total remaining life.

[0047] In some embodiments, the branch manager 155 may select a subset of the branches 135 based on the individual usage metrics of each branch 135. For example, the branch manager 155 may identify individual branches 135 equal to the number of branches 135 to be used that have the lowest total utilization time or the highest remaining life. In this example, when two branches are to be used, the branch manager 155 may select the two branches 135 with the lowest total utilization time or the highest remaining life. In some embodiments, the branch manager 155 may select a subset of branches 135 that are identified as previously unused (e.g., during a recent delivery of power through the power converter 120). The branch manager 155 may identify at least one branch 135 to include in the subset of branches 135 to be activated based on an identification that the branch 135 was not activated when power was previously delivered through the power converter 120.

[0048] In some embodiments, the branch manager 155 can identify or determine whether to reselect the previously activated group of branches 135 based on the amount of time that has passed since the previous activation of the branch 135. The amount of time that has passed can be determined from the usage history log of each branch 135 of the power converter 120. To determine, the branch manager 155 can compare the elapsed time to a threshold. The threshold can depict, define, or otherwise specify a value of the elapsed time to reselect a previously activated group of branches 135. If the elapsed time does not exceed (e.g., is less than or equal to) the threshold, the branch manager 155 can determine to exclude the group of branches 135 from reselection. Otherwise, if the elapsed time exceeds (e.g., is greater than) the threshold, the branch manager 155 can determine to reselect the group of branches 135 for activation.

[0049] By selection, the branch manager 155 can enable, open or otherwise activate the selected branch 135 to transfer power between the power source 110 and the load 115. The branch manager 155 can enable, open or activate the selected branch 135. In some embodiments, the branch manager 155 can provide, send or otherwise transmit a command signal to the power converter 120 to activate each selected branch 135. In some embodiments, the branch manager 155 can engage, connect or otherwise couple each selected branch 135 in the power converter 120 with the power source 110 and the load 115 to allow power to be transferred. Conversely, the branch manager 155 can disable, close or otherwise deactivate the remaining branches 135 that are not selected for activation. The branch manager 155 can cause the remaining branches 135 to be disabled, closed or deactivated. In some embodiments, the branch manager 155 can provide, send or otherwise transmit a command signal to the power converter 120 to deactivate each unselected branch 135. In some embodiments, branch manager 155 may disengage, disconnect, or otherwise decouple each remaining branch 135 in power converter 120 from power source 110 and load 115 to prevent power from being delivered through unselected branches 135 .

[0050] The power converter 120 can transmit power between the power source 110 and the load 115 through the activated branch 135. The power converter 120 can be configured to be coupled to the power source 110 and the load 115. The power converter 120 can also be configured to be coupled to the controller 125 in the power subsystem 105. When activated, the branch 135 of the power converter 120 can perform conversion (e.g., DC to DC voltage conversion) on the power transmitted between the power source 110 and the load 115. When deactivated, the branch 135 of the power converter 120 can be disconnected from the coupling between the power source 110 and the load 115, so that power is not transmitted through the branch 135.

[0051] As branches 135 in power converter 120 are activated or deactivated, controller 125 and its components may repeat the functions detailed above. Sensor 130 may monitor input and output voltages so that duty cycle may be calculated. As power flows, controller 125 may continue to measure, determine, or otherwise identify duty cycle. Controller 125 may calculate duty cycle based on voltage measured by sensor 130. Controller 125 may determine whether a measured parameter has changed by a threshold margin relative to a previously measured parameter based on a duty cycle or power command received from a higher-level system controller. For example, the range of the threshold margin may be a change of at least 0-10% of the value of the measured parameter. The threshold margin may be set to ensure that there are a sufficient number of branches for power commands.

[0052] Based on this determination, the branch manager 155 can re-determine the number of branches 135 to be used. If it is determined that the parameters defining the power have changed (e.g., as determined by a margin determination), the branch manager 155 can re-determine the number of branches 135 to be used and reselect the group of branches 135 to be activated accordingly. The functions of the branch manager 155 can be repeated as described above. Otherwise, if it is determined that the parameters defining the power have not changed (e.g., as determined by a margin determination), the branch manager 155 can continue to monitor the parameters of the power. In addition, the branch manager 155 can maintain the activation of the same branches 135 to deliver power between the power source 110 and the load 115.

[0053] At the same time, the utilization meter 150 can monitor the usage of the selected group of branches 135 of the power converter 120. When power is transmitted between the power source 110 and the branches 135, the utilization meter 150 can measure, identify, or otherwise determine a relative usage metric for each activated branch 135. The relative usage metric can identify or correspond to the degree of usage of the corresponding branch 135 in the power converter 120 compared to before the given branch 135 was activated. The relative usage metric can identify or include, for example, the total usage duration of the branch 135 or the total remaining useful life (RUL) of the branch 135.

[0054] With this determination, the utilization meter 150 can compare the relative usage metric to a threshold measurement. The threshold measurement can depict, identify, or define a value of the relative usage metric at which another subset of the branches 135 is reselected to be activated to deliver power through the power converter 120. When the relative usage metric meets (e.g., is greater than or equal to) the threshold measurement, the utilization meter 150 can call the branch manager 155 to reselect another subset of the branches 135 for activation. The functions of the branch manager 155 can be repeated as described above. Conversely, when the relative usage metric does not meet (e.g., is less than) the threshold measurement, the utilization meter 150 can continue to monitor the usage of the selected group of branches 135. In addition, the branch manager 155 can maintain the activation of the same branches 135 to deliver power between the power source 110 and the load 115.

[0055] Reference now Figure 2 , which depicts a flow chart of a method 200 for selectively activating one or more branches of a power converter. Method 200 may be performed or implemented using any of the components herein, such as power subsystem 105 and components thereof (e.g., power converter 120 and controller 125). Under method 200, a controller (e.g., controller 125) may identify a parameter of an operating condition (205). The controller may determine, based on the parameter, a number of branches (e.g., branch 135) of a power converter (e.g., power converter 120) to be used to deliver power (210). The controller may identify a usage metric for each branch in the power converter (215). The controller may select at least a subset of the branches in the power converter for activation based on the number of branches and the usage metric for each branch (220).

[0056] Reference now Figure 3 , shows the input current ripple (ΔI in ) versus duty cycle (D). Graph 300 illustrates that an optimal number of branches may be identified based on the duty cycle (D) of the power to minimize the current ripple (ΔI) in the power delivered between power source 110 and load 115 through power converter 120. in ). Now refer to Figure 4 , a graph 400 showing converter efficiency versus input power for different numbers of branches of the power converter being activated is shown. Graph 400 shows that an optimal number of branches can be identified to optimize power delivery efficiency. Graphs 300 and 400 can be used to define a function that determines the number of branches 135 to be activated.

[0057] Reference now Figures 5A-5E, depicts a flow chart of a method 500 for determining the number of branches and selectively activating the branches. The method 500 may be performed or implemented using any of the components herein, such as the power subsystem 105 and its components (e.g., the power converter 120 and the controller 125). Figure 5A Initially, under method 500, a controller (e.g., controller 125) may determine the number of branches to use (e.g., branches 135 of power converter 120) based on a power command and a duty cycle to improve efficiency or reduce current ripple (502) according to the power command and the duty cycle. The controller may identify whether a branch is operating normally or has failed (503). Based on the power command and the duty cycle, the controller may determine to use one branch (504) for A, two branches (506) for B, three branches (508) for C, or four branches (510) for D, etc.

[0058] Go to Figure 5B , when the number of branches to be used is 1, the controller can determine which branches were previously used and select another branch that was not previously used (520). In some embodiments, the controller can determine the total utilization time of each branch and select the branch with the lowest utilization time (522). In some embodiments, the controller can determine the remaining life of each branch and select the branch with the longest remaining life (524). By selecting and activating the branches, the controller can monitor changes in the power command or duty cycle (526). If a change in the power command or duty cycle is detected, the controller can proceed to E to repeat step (502). Otherwise, if no change is detected, the controller can determine whether the operating time of the selected branch is greater than a threshold or whether the consumed life is greater than a threshold (528). If the operating time or the consumed life is greater than the corresponding threshold, the controller can repeat from E. Otherwise, if the operating time or the consumed life is less than the corresponding threshold, the controller can repeat step (526).

[0059] Go to Figure 5C , when the number of branches to be used is 2, the controller can determine the total utilization or remaining life of each predefined branch pair (e.g., the first branch 135A and the third branch 135C; the first branch 135A and the fourth branch 135D; or the second branch 135B and the fourth branch 135D), and select the predefined branch pair with the lowest utilization or the longest remaining life (540). In some embodiments, the controller can determine the total utilization time of each branch and select the two branches with the lowest utilization time (542). In some embodiments, the controller can determine which branches were previously used and select branches that were not previously used (544). In some embodiments, the controller can determine the remaining life of each branch and select the branch with the longest remaining life (546).

[0060] By selecting and activating the branches, the controller can monitor the change of the power command or duty cycle (548). If a change of the power command or duty cycle is detected, the controller can proceed to E to repeat step (502). Otherwise, if no change is detected, the controller can determine whether the operation time of each branch in the selected branches is greater than a threshold or whether the consumed life is greater than a threshold (550). If the operation time or the consumed life is greater than the corresponding threshold, the controller can repeat from E. Otherwise, if the operation time or the consumed life is less than the corresponding threshold, the controller can repeat step (548).

[0061] Go to Figure 5D , when the number of branches to be used is 3, the controller can determine the total utilization or remaining life of a predefined group of three branches (e.g., branches 135A, 135C, and 135D, branches 135A, 135B, and 135D, etc.), and select the group with the lowest utilization or remaining life (560). In some embodiments, the controller can determine the total utilization time of each branch, and select the group of three branches with the lowest utilization time (562). In some embodiments, the controller can determine which branches were previously used, and select a previously unused branch (e.g., a group of three branches with at least one previously unused branch) (564). In some embodiments, the controller can determine the remaining life of each branch, and select the branch with the longest remaining life (566).

[0062] By selecting and activating the branches, the controller can monitor for changes in the power command or duty cycle (568). If a change in the power command or duty cycle is detected, the controller can repeat step E starting from step (502). Otherwise, if no change is detected, the controller can determine whether the operating time of each branch in the selected branches is greater than a threshold or whether the consumed life is greater than a threshold (570). If the operating time or the consumed life is greater than the corresponding threshold, the controller can repeat from E. Otherwise, if the operating time or the consumed life is less than the corresponding threshold, the controller can repeat from step (568).

[0063] Go to Figure 5E , when the number of branches to be used is 4, the controller may select all four branches of the converter (580). By selecting and activating the branches, the controller may monitor for changes in the power command or duty cycle (582). If a change in the power command or duty cycle is detected, the controller may proceed to E to repeat step (502). Otherwise, if no change in the power command or duty cycle is detected, the controller may continue to use all four branches and repeat from (580).

[0064] For purposes of this disclosure, the term "coupled" means that two components are directly or indirectly connected or linked to each other. Such a connection may be fixed or movable in nature. For example, a drive shaft of an engine is "coupled" to a transmission to represent a movable connection. Such a connection may be achieved with two components or with two components and any additional intermediate components. For example, circuit A is communicatively "coupled" to circuit B to represent that circuit A communicates directly with circuit B (i.e., without an intermediary) or communicates indirectly with circuit B (e.g., through one or more intermediaries).

[0065] Although various circuits with specific functions are shown in the drawings, it should be understood that the assembly may include any number of circuits for performing the functions described herein. For example, the activities and functions of the circuits of system 100 may be combined in multiple circuits or in a single circuit. Additional circuits with additional functions may also be included. In addition, the controller may also control other activities beyond the scope of the present disclosure.

[0066] As described above, in one configuration, a "circuit" can be implemented in a machine-readable medium for execution by various types of processors. For example, the circuit of the identified executable code may include one or more physical or logical blocks of computer instructions, such as being organized as objects, processes, or functions. However, the executable files of the identified circuit do not need to be physically located together, but may include scattered instructions stored in different locations, which, when logically connected together, constitute the circuit and achieve the purpose of the circuit. In fact, the circuit of the computer-readable program code can be a single instruction or many instructions, and can even be distributed on several different code segments, between different programs, and on several memory devices. Similarly, operating data can be identified and explained within the circuit, and the operating data can be implemented in any suitable form and organized in any suitable type of data structure. The operating data can be collected as a single data set, or can be distributed on different locations including different storage devices, and can exist at least partially only as electronic signals on a system or network.

[0067] Although the term "processor" is briefly defined above, the terms "processor" and "processing circuit" are intended to be interpreted broadly. In this regard and as described above, a "processor" may be implemented as one or more general-purpose processors, application-specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), digital signal processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by a memory. One or more processors may take the form of a single-core processor, a multi-core processor (e.g., a dual-core processor, a triple-core processor, a quad-core processor, etc.), a microprocessor, etc. In some embodiments, one or more processors may be located outside the device, for example, one or more processors may be remote processors (e.g., cloud-based processors). Alternatively or additionally, one or more processors may be internal and / or local to the device. In this regard, a given circuit or its components may be arranged locally (e.g., as part of a local server, a local computing system, etc.) or remotely (e.g., as part of a remote server (e.g., a cloud-based server)). To this end, a "circuit" as described herein may include components distributed in one or more locations.

[0068] Although the diagrams herein may illustrate the specific order and composition of the method steps, the order of these steps may be different from the order depicted. For example, two or more steps may be performed simultaneously or partially simultaneously. In addition, some method steps performed as discrete steps may be combined, steps performed as combined steps may be divided into discrete steps, the order of certain processes may be reversed or otherwise changed, and the nature or quantity of the separated processes may be changed or varied. According to alternative embodiments, the order or sequence of any element or device may be changed or replaced. All such modifications are intended to be included within the scope of the present disclosure as defined by the appended claims. These changes will depend on the selected machine-readable medium and hardware system and the choice of the designer. All these changes are within the scope of the present disclosure.

[0069] The above description of the embodiments is presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations may be made in light of the above teachings or may be derived from the present disclosure. The embodiments are selected and described in order to explain the principles of the present disclosure and its practical application to enable those skilled in the art to utilize various implementations and various modifications suitable for the specific use contemplated. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure as expressed in the appended claims.

[0070] Therefore, the present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are considered in all respects to be illustrative and not restrictive. Therefore, the scope of the present disclosure is indicated by the appended claims rather than the preceding description. All changes within the meaning and scope of the equivalents of the claims will be included within their scope.

Claims

1. A system for selectively activating branches of a converter, characterized in that include: A power converter, the power converter comprising a plurality of branches for converting power transmitted between a power source and a load; and A controller configured to be coupled to the power converter, the controller having one or more processors coupled to a memory, the control device being configured to: identifying parameters defining operating conditions of the power converter; determining a number of branches of the power converter to use based on the parameter; identifying a metric indicative of utilization of each of the plurality of branches; and At least a subset of the plurality of branches is activated based on the number of branches and the metric such that the at least the subset of branches transfers power between the power source and the load.

2. The system according to claim 1, characterized in that The controller is also configured to: monitoring changes in parameters defining power delivered by a subset of the branches of the power converter; and In response to detecting the change, a number of the branches of the plurality of branches for transmitting power between the power source and the load is re-determined based on the parameter.

3. The system according to claim 1, characterized in that The controller is also configured to: monitoring the time that has elapsed since at least a subset of the branches were activated to deliver power; and In response to the elapsed time exceeding a threshold, a determination is made to reselect the at least a subset of the branches from the plurality of branches.

4. The system according to claim 1, characterized in that The controller is also configured to: determining that the number of the branches of the power converter to be used is less than the total number of branches available for use; identifying at least one second branch from the plurality of branches corresponding to the number of branches of the power converter to be used; and At least a subset of branches is selected from the plurality of branches based on the number of branches and a metric indicative of utilization of each branch of the at least one second branch.

5. The system according to claim 1, characterized in that The controller is also configured to: determining that the number of the branches of the power converter to be used is less than the total number of branches available for use; In response to determining that the number of branches to be used is less than the total number of branches, identifying a plurality of metrics for a subset of a corresponding plurality of branches in the plurality of branches, each of the plurality of metrics corresponding to a respective utilization of a corresponding subset of the subset of the plurality of branches; and The at least a subset of branches is selected from the subset of the plurality of branches based on the plurality of metrics.

6. The system according to claim 1, characterized in that The controller is also configured to: determining that the number of branches of the power converter to be used is equal to the total number of branches available for use; and In response to determining that the number of branches to be used is equal to the total number, the plurality of branches are selected for activation.

7. The system according to claim 1, characterized in that The parameter includes at least one of a duty cycle or a power command, and wherein the metric identifies at least one of a total utilization or a remaining lifetime.

8. A method for managing a branch of a converter, characterized in that include: identifying, by the controller, parameters defining operating conditions of the power converter; determining, by the controller, a number of branches of the power converter to be used based on the parameter; identifying, by the controller, a metric indicative of utilization of each of a plurality of branches of the power converter; and At least one branch of the plurality of branches is activated by the controller according to the number of branches and the metric, so that the at least one branch transfers power between a power source and a load.

9. The method according to claim 8, characterized in that Also includes: monitoring, by the controller, changes in a parameter defining power delivered through at least one branch of the power converter; and In response to detecting the change, the number of branches to be used is re-determined by the controller based on the parameter.

10. The method according to claim 8, characterized in that Also includes: monitoring, by the controller, a time that has elapsed since the at least one branch was activated to deliver power; and In response to the elapsed time exceeding a threshold, the controller determines to reselect the at least one branch from a plurality of branches.

11. The method according to claim 8, characterized in that Also includes: The controller determines that the number of branches of the power converter to be used is less than the total number of branches available for use; identifying, by the controller, at least one second branch from the plurality of branches corresponding to the number of branches of the power converter to be used; and The at least one second branch is selected by the controller from at least one second branch of the branches based on the number of the branches and a metric indicative of utilization of the at least one second branch.

12. The method according to claim 8, characterized in that Also includes: The controller determines that the number of branches of the power converter to be used is less than the total number of branches available for use; In response to determining that the number of branches to be used is less than the total number of branches, identifying, by the controller, a plurality of metrics for a subset of a corresponding plurality of branches in the plurality of branches, each of the plurality of metrics corresponding to a respective utilization rate of a corresponding subset of the subset of the plurality of branches; and At least one branch is selected, by a controller, from a subset of the plurality of branches based on the plurality of metrics.

13. The method according to claim 8, characterized in that Also includes: Determining, by a controller, that the number of branches of the power converter to be used is equal to the total number of branches available for use; and In response to determining that the number of the branches to be used is equal to the total number, the plurality of branches are selected by the controller for activation.

14. The method according to claim 8, characterized in that The parameter includes at least one of a duty cycle or a power command, and wherein the metric identifies at least one of a total utilization or a remaining lifetime.

15. A device for controlling a power converter, characterized in that: include: One or more processors coupled to the memory, the one or more processors configured to: identifying parameters defining operating conditions of the power converter; determining a number of branches of the power converter to use based on the parameter; identifying a metric indicative of utilization of each of the plurality of branches; and A subset of the branches of the plurality of branches is activated based on the number of branches and the metric such that the subset of branches transfers power between a power source and a load.

16. The device according to claim 15, characterized in that The one or more processors are configured to: monitoring changes in parameters defining power delivered by a subset of the branches of the power converter; and In response to detecting the change, the number of the branches to be used is re-determined based on the parameter.

17. The device according to claim 15, characterized in that The one or more processors are configured to: monitoring the time that has elapsed since a subset of the branches were activated to deliver power; and In response to the elapsed time exceeding a threshold, a determination is made to reselect a subset of the branches from the plurality of branches.

18. The device according to claim 15, characterized in that The one or more processors are configured to: determining that the number of the branches of the power converter to be used is less than the total number of branches available for use; identifying, from the plurality of branches, a second subset of branches corresponding to a number of branches of the power converter to be used; and The subset of branches is selected from the second subset of branches based on the number of branches and a metric indicative of utilization of each branch of the second subset of branches.

19. The device according to claim 15, characterized in that The one or more processors are configured to: determining that the number of the branches of the power converter to be used is less than the total number of branches available for use; In response to determining that the number of branches to be used is less than the total number of branches, identifying a plurality of metrics for a subset of a corresponding plurality of branches in the plurality of branches, each of the plurality of metrics corresponding to a respective utilization of a corresponding subset of the subset of the plurality of branches; and The subset of branches is selected from the subset of the plurality of branches based on the plurality of metrics.

20. The device according to claim 15, characterized in that The parameter includes at least one of a duty cycle or a power command, and wherein the metric identifies at least one of a total utilization or a remaining lifetime.

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