Variable phase power converter

Abstract

A power converter includes a power factor correction circuit and a controller. The power factor correction circuit is configured to convert an input single-phase electrical power to a first DC electrical power. Active phases of input single-phase electrical power are received in parallel through two of the four conductors. The return phase of the input single-phase electrical power is received in parallel through two other conductors of the four conductors. The power factor correction circuit is further configured to convert the input three-phase electrical power to a first DC electrical power. Three active phases of input three-phase electrical power are received through three of the four conductors. The return phase is received through a fourth one of the four conductors. The controller is configured to control the power factor correction circuit to operate in a single-phase input mode and a three-phase input mode in response to a control signal.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Application No. 17 / 895,021, filed on August 24, 2022, which is incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to systems and methods for variable phase power conversion. Background Art

[0004] Existing electric vehicles have an onboard charging device that converts three-phase alternating current (AC) power to direct current (DC) power to charge the onboard battery. The charging device implements a power line sized to accommodate the active phase current received from the charging station. In some designs, a larger return line is implemented to accommodate the ground current in the four-wire star (Y) configuration of the charging station.

[0005] Therefore, those skilled in the art continue to make great efforts in research and development in the field of vehicle AC charging. Summary of the invention

[0006] A power converter is provided herein. The power converter includes a power factor correction circuit and a controller. The power factor correction circuit has an electrical interface with four interface conductors. The power factor correction circuit is configured to convert the input single-phase electric power into a first DC electric power when operating in a single-phase input mode. The active phase of the input single-phase electric power is received in parallel through the first conductor and the second conductor of the four interface conductors. The return phase of the input single-phase electric power is received in parallel through the third conductor and the fourth conductor of the four interface conductors. The power factor correction circuit is also configured to convert the input three-phase electric power into a first DC electric power when operating in a three-phase input mode. The first phase of the input three-phase electric power is received through the first conductor of the four interface conductors. The second phase of the input three-phase electric power is received through the second conductor of the four interface conductors. The third phase of the input three-phase electric power is received through the third conductor of the four interface conductors. The return phase of the input three-phase electric power is received through the fourth conductor of the four interface conductors. The controller is configured to control the power factor correction circuit to operate in a single-phase input mode in response to a first command received via a control signal, and to control the power factor correction circuit to operate in a three-phase input mode in response to a second command received via the control signal.

[0007] In one or more embodiments of the power converter, the power factor correction circuit includes: four inductors, the four inductors are respectively connected in series with four interface conductors, wherein the four interface conductors are configured to transmit four currents; a plurality of first transistors, the plurality of first transistors are controlled by a controller to selectively switch the four inductors to a first power bus; and a plurality of second transistors, the plurality of second transistors are controlled by the controller to selectively switch the four inductors to a second power bus, wherein a first DC electric power is established between the first power bus and the second power bus.

[0008] In one or more embodiments of the power converter, when in single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being rising, the plurality of second transistors switch the four inductors to the second power bus.

[0009] In one or more embodiments of the power converter, when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, a plurality of first transistors switch two of the four inductors to a first power bus, and when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, a plurality of second transistors switch two of the four inductors to a second power bus.

[0010] In one or more embodiments of the power converter, when in single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being rising, the plurality of second transistors switch the four inductors to the second power bus.

[0011] In one or more embodiments of the power converter, when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, a plurality of first transistors switch two of the four inductors to a first power bus, and when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, a plurality of second transistors switch two of the four inductors to a second power bus.

[0012] In one or more embodiments, the power converter includes a DC to DC converter configured to convert the first DC electric power into a second DC electric power having a different voltage than the first DC electric power.

[0013] In one or more embodiments of the power converter, the power factor correction circuit is further configured to: when operating in a single-phase output mode, convert the first DC electric power into output single-phase electric power; provide the output single-phase electric power at the electrical interface; when operating in a three-phase output mode, convert the first DC electric power into output three-phase electric power; and provide the output three-phase electric power at the electrical interface. The controller is also configured to control the power factor correction circuit to operate in the single-phase output mode in response to a third command received via the control signal, and to control the power factor correction circuit to operate in the three-phase output mode in response to a fourth command received via the control signal.

[0014] In one or more embodiments of the power converter, the power factor correction circuit and controller are implemented in a vehicle.

[0015] A method for power conversion is provided herein. The method includes receiving electric power through four interface conductors of an electrical interface of a power factor correction circuit, and converting the input single-phase electric power into a first DC electric power in a power factor correction circuit operating in a single-phase input mode. The active phase of the input single-phase electric power is received in parallel through the first conductor and the second conductor of the four interface conductors. The return phase of the input single-phase electric power is received in parallel through the third conductor and the fourth conductor of the four interface conductors. The method also includes converting the input three-phase electric power into a first DC electric power in a power factor correction circuit operating in a three-phase input mode. The first phase of the input three-phase electric power is received through the first conductor of the four interface conductors. The second phase of the input three-phase electric power is received through the second conductor of the four interface conductors. The third phase of the input three-phase electric power is received through the third conductor of the four interface conductors. The return phase of the input three-phase electric power is received through the fourth conductor of the four interface conductors. The method includes controlling the power factor correction circuit to operate in a single-phase input mode with a controller in response to a first command received via a control signal, and controlling the power factor correction circuit to operate in a three-phase input mode with a controller in response to a second command received via a control signal.

[0016] In one or more embodiments of the method, the power factor correction circuit includes four inductors, and the four inductors are respectively connected in series with four interface conductors. The four interface conductors are configured to transmit four currents. The power factor correction circuit includes: a plurality of first transistors, the plurality of first transistors are controlled by a controller to selectively switch the four inductors to a first power bus; and a plurality of second transistors, the plurality of second transistors are controlled by the controller to selectively switch the four inductors to a second power bus. The first DC electric power is established between the first power bus and the second power bus.

[0017] In one or more embodiments, the method includes: when in single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being rising, switching the four inductors to a second power bus through a plurality of second transistors.

[0018] In one or more embodiments, the method includes: when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, switching two of the four inductors to a first power bus through a plurality of first transistors; and when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, switching two of the four inductors to a second power bus through a plurality of second transistors.

[0019] In one or more embodiments, the method includes: when in single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being rising, switching the four inductors to a second power bus through a plurality of second transistors.

[0020] In one or more embodiments, the method includes: when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, switching two of the four inductors to a first power bus through a plurality of first transistors; and when in a single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, switching two of the four inductors to a second power bus through a plurality of second transistors.

[0021] In one or more embodiments, the method includes converting a first DC electric power to a second DC electric power, wherein the second DC electric power has a different voltage than the first DC electric power.

[0022] In one or more embodiments, the method includes: converting a first DC electric power into output single-phase electric power in a power factor correction circuit operating in a single-phase output mode; providing the output single-phase electric power at an electrical interface; converting the first DC electric power into output three-phase electric power in a power factor correction circuit operating in a three-phase output mode; presenting the output three-phase electric power at the electrical interface; controlling the power factor correction circuit to operate in the single-phase output mode in response to a third command received via a control signal; and controlling the power factor correction circuit to operate in the three-phase output mode in response to a fourth command received via the control signal.

[0023] A vehicle is provided herein. The vehicle includes a charging socket, a power factor correction circuit, and a controller. The charging socket has at least four socket conductors. The power factor correction circuit is electrically connected to the charging socket. The power factor correction circuit is configured to convert the input single-phase electric power into a first DC electric power when operating in a single-phase input mode. The active phase of the input single-phase electric power is received in parallel through the first socket conductor and the second socket conductor of the four socket conductors. The return phase of the input single-phase electric power is received in parallel through the third socket conductor and the fourth socket conductor of the four socket conductors. The power factor correction circuit is configured to convert the input three-phase electric power into a first DC electric power when operating in a three-phase input mode. The first phase of the input three-phase electric power is received through the first socket conductor of the four socket conductors. The second phase of the input three-phase electric power is received through the second socket conductor of the four socket conductors. The third phase of the input three-phase electric power is received through the third socket conductor of the four socket conductors. The return phase of the input three-phase electric power is received through the fourth socket conductor of the four socket conductors. The controller is configured to control the power factor correction circuit to operate in a single-phase input mode in response to a first command received via a control signal, and to control the power factor correction circuit to operate in a three-phase input mode in response to a second command received via the control signal.

[0024] In one or more embodiments, the vehicle includes a DC to DC converter configured to bidirectionally convert between a first DC electric power and a second DC electric power. The second DC electric power has a voltage different from the first DC electric power. The vehicle includes a battery pack electrically coupled to the DC to DC converter, the battery pack being configured to receive the second DC electric power from the DC to DC converter when in a charging mode, and being configured to provide the second DC electric power to the DC to DC converter when in a discharging mode.

[0025] In one or more embodiments of the vehicle, the power factor correction circuit is further configured to: when operating in a single-phase output mode, convert the first DC electric power into output single-phase electric power; provide the output single-phase electric power to the charging socket; when operating in a three-phase output mode, convert the first DC electric power into output three-phase electric power; and provide the output three-phase electric power to the charging socket. The controller is also configured to control the power factor correction circuit to operate in the single-phase output mode in response to a third command received via the control signal, and to control the power factor correction circuit to operate in the three-phase output mode in response to a fourth command received via the control signal.

[0026] The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the present teachings when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a schematic diagram illustrating the context of a system according to one or more exemplary embodiments.

[0028] Figure 2 is a schematic block diagram of a power converter according to one or more exemplary embodiments.

[0029] Figure 3 is a schematic diagram of a charging receptacle according to one or more exemplary embodiments.

[0030] Figure 4 is a schematic diagram of a power factor correction circuit and a DC-to-DC converter according to one or more exemplary embodiments.

[0031] Figure 5 is a schematic diagram of inductor charging in a single-phase input mode according to one or more exemplary embodiments.

[0032] Figure 6 is a schematic diagram of inductor discharge in a single-phase input mode according to one or more exemplary embodiments.

[0033] Figure 7 is a schematic diagram of additional inductor charging in single-phase input mode according to one or more exemplary embodiments.

[0034] Figure 8 is a schematic diagram of additional inductor discharge in single-phase input mode according to one or more exemplary embodiments.

[0035] Fig. 9 is a schematic diagram of inductor charging in a three-phase input mode according to one or more exemplary embodiments.

[0036] Fig.10 is a schematic diagram of inductor discharge in a three-phase input mode according to one or more exemplary embodiments.

[0037] Fig.11 is a flow chart of a method for power conversion according to one or more exemplary embodiments.

[0038] Fig.12 is a flow chart of a method for receiving single-phase electrical power according to one or more exemplary embodiments.

[0039] Fig.13 is a flow chart of a method for receiving three-phase electric power according to one or more exemplary embodiments.

[0040] Fig.14 is a flow chart of a method for providing single-phase electrical power according to one or more exemplary embodiments.

[0041] Fig.15 is a flow chart of a method for providing three-phase electric power according to one or more exemplary embodiments.

[0042] The present disclosure may have various modifications and alternative forms, and some representative embodiments are shown by way of example in the accompanying drawings and will be described in detail herein. The novel aspects of the present disclosure are not limited to the specific forms shown in the above-mentioned drawings. Instead, the present disclosure will cover modifications, equivalents, and combinations that fall within the scope of the present disclosure as contained in the appended claims. DETAILED DESCRIPTION

[0043] Embodiments of the present disclosure generally provide a power converter using a three-phase totem pole as a power factor correction (PFC) topology. The power converter can be unidirectional and / or bidirectional. For in-vehicle applications, the power converter implements an on-board charger (OBC), which converts alternating current (AC) electrical power to direct current (DC) electrical power (e.g., during battery charging) and / or vice versa when the direction of electrical power transmission is reversed (e.g., in vehicle-to-the-world (V2X)). Battery charging can be Level 1 AC charging and / or Level 2 AC charging.

[0044] The power converter includes a bridgeless totem pole power factor correction circuit, a DC to DC converter and a controller. The power factor correction circuit has four conductors for AC electric power. These conductors are called the first line (L1), the second line (L2), the third line (L3) and the neutral line (N). When operating with single-phase AC electric power, two conductors (e.g., L1 and L2) are used in parallel to carry the active phase of the electric power, and the other two conductors (e.g., L3 and N) are used in parallel to carry the return phase. When operating with three-phase AC electric power, three conductors (e.g., L1, L2 and L3) are used to carry the three corresponding active phases of the electric power, and one conductor (e.g., N) is used to carry the return phase.

[0045] refer to Figure 1 , a schematic diagram showing the background of a system 70 is shown, according to one or more exemplary embodiments. The system 70 generally includes a charging station 72 and a vehicle 90. The charging station 72 includes a charging cable 74 and a charging plug 76. The vehicle 90 includes a charging receptacle 92, a battery pack 98, and a power converter 100.

[0046] The electrical power 78 can flow in either direction between the charging station 72 and the power converter 100 via the charging cord 74, the charging plug 76, and the charging receptacle 92. In some cases, the electrical power 78 can be single-phase alternating current (AC) electrical power. In other cases, the electrical power 78 can be three-phase AC electrical power.

[0047] The control signal 80 may be provided from the charging plug 76 to the power converter 100 through the charging receptacle 92. The control signal 80 may transmit one of a plurality of commands 82 to the power converter 100. The command 82 instructs the power converter 100 the number of phases of the electrical power 78 and the direction in which the electrical power 78 is flowing (e.g., into the power converter 100 via the charging receptacle 92 or out of the charging receptacle 92).

[0048] Communication signals 84 may be exchanged between charging station 72 and power converter 100 via charging cord 74, charging plug 76, and charging receptacle 92. Communication signals 84 may provide standard signaling information between charging station 72 and power converter 100 to start, control, and stop the flow of electrical power 78.

[0049] The charging station 72 is operable to provide electrical power (e.g., current at a voltage) to the vehicle 90 to recharge the onboard battery of the vehicle 90. In various embodiments, the charging station 72 can comply with the SAE International J1772 standard and / or the International Electrotechnical Commission (IEC) 61851-1 standard. The charging station 72 can be a Level 1 AC charger or a Level 2 AC charger. Other charging standards can be implemented to meet the design criteria of a specific application. Some charging stations 72 can be placed in fixed locations. Other charging stations 72 can be mobile.

[0050] The charging plug 76 implements an electric charging handle. The charging socket 92 implements a vehicle charging inlet. The charging plug 76 can be connected and disconnected with the charging socket 92. The charging plug 76 and the charging socket 92 are operable to transmit electric power 78, control signals 80, and communication signals 84 between the charging station 72 and the vehicle 90.

[0051] The vehicle 90 implements an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle. In various embodiments, the vehicle 90 may comply with the SAE International J1772 standard and / or the International Electrotechnical Commission (IEC) 61851-1 standard. The vehicle 90 may implement a Level 1 AC and / or Level 2 AC charging capability. Other standards may be implemented to meet the design criteria of a particular application. In various embodiments, the vehicle 90 may include, but is not limited to, a passenger car, a truck, an autonomous car, a motorcycle, a boat, and / or an airplane. In some embodiments, the vehicle 90 may be a fixed object, such as a room, a stall, and / or a building. Other types of vehicles 90 may be implemented to meet the design criteria of a particular application.

[0052] The battery pack 98 is implemented as a high voltage rechargeable energy storage system. The battery pack 98 is configured to store electrical energy. The battery pack 98 is generally operable to receive electrical power from the power converter 100 and to provide electrical power to the power converter 100. The battery pack 98 may include a plurality of battery modules electrically connected in series and / or in parallel. In various embodiments, the battery pack 98 may provide a potential of approximately 200 to 1000 volts DC (direct current). Other battery voltages may be implemented to meet the design criteria of a particular application.

[0053] The power converter 100 is operable to accept or alternately provide single-phase AC electric power and three-phase AC electric power (e.g., electric power 78). When operating in a single-phase input mode, the power converter 100 is operable to convert the input single-phase electric power into a first direct current (DC) electric power. The first DC electric power can be converted into a second DC current suitable for charging the battery pack 98. When operating in a three-phase input mode, the power converter 100 is operable to convert the input three-phase electric power into a first DC electric power. The first DC electric power can be converted into a second DC electric power suitable for charging the battery pack 98. When operating in a single-phase output mode, the power converter 100 can receive a second DC electric power from the battery pack 98, and convert the second DC electric power into a first DC electric power, and then convert the first DC electric power into an output single-phase AC electric power. When operating in a three-phase output mode, the power converter 100 can receive a second DC electric power from the battery pack 98, and convert the second DC electric power into a first DC electric power, and then convert the first DC electric power into an output three-phase AC electric power. In various implementations, power converter 100 may be located in vehicle 90. In other implementations, power converter 100 may be located in a fixed location.

[0054] refer to Figure 2 , a schematic block diagram of an example implementation of a power converter 100 is shown, according to one or more exemplary embodiments. The power converter 100 generally includes a power factor correction circuit 110, a controller 140, and a DC to DC converter 150. The power factor correction circuit 110 includes an electrical interface 112 and a first DC electrical interface 124.

[0055] The electrical power 78 is connected to the electrical interface 112 of the power factor correction circuit 110 and to the controller 140. The control signal 80 is received by the controller 140. The switching signal 128 is generated by the controller 140 and received by the power factor correction circuit 110. The switching signal 128 carries switching information for controlling the power factor correction circuit 110. The DC conversion signal 142 is generated by the controller 140 and provided to the DC to DC converter 150. The DC conversion signal 142 conveys more switching information for controlling the DC to DC converter 150.

[0056] The power factor correction circuit 110 implements a bridgeless totem pole power factor correction circuit. The power factor correction circuit 110 can operate in a single-phase input mode to convert a single-phase AC electric power 78 received at the electrical interface 112 into a first DC electric power 126 at the first DC electrical interface 124 as controlled by a switching signal 128. In a three-phase input mode, the power factor correction circuit 110 can operate to convert a three-phase AC electric power 78 received at the electrical interface 112 into a first DC electric power 126 at the first DC electrical interface 124 as controlled by a switching signal 128. The power factor correction circuit 110 can operate in a single-phase output mode to convert a first DC electric power 126 at the first DC electrical interface 124 into a single-phase AC electric power 78 provided at the electrical interface 112 as controlled by a switching signal 128. In the three-phase output mode, the power factor correction circuit 110 is operable to convert the first DC electrical power 126 received at the first DC electrical interface 124 into the three-phase AC electrical power 78 provided at the electrical interface 112 as controlled by the switching signal 128 .

[0057] The controller 140 implements one or more processors that execute software. The software may be stored in a non-transitory computer readable medium (e.g., non-volatile memory). The software, when executed by the processor, may cause the processor to generate the switching signal 128 and the DC conversion signal 142. The generation of the switching signal 128 and the DC conversion signal 142 is based on the voltage and phase of the electric power signal 78, the command 82 in the control signal 80, and the information in the communication signal 84.

[0058] The DC-to-DC converter 150 implements a unidirectional and / or bidirectional converter of DC electric power. The operation of the DC-to-DC converter 150 is controlled by the controller 140 via a DC conversion signal 142. In a charging operation mode, the DC-to-DC converter 150 converts a first DC electric power 126 received at the first DC electrical interface 124 into a second DC electric power 154 provided at the second DC electrical interface 152. In a discharging operation mode, the DC-to-DC converter 150 converts a second DC electric power 154 received at the second DC electrical interface 152 into a first DC electric power 126 at the first DC electrical interface 124. The second DC electric power 154 typically has a different (e.g., higher) voltage (e.g., 800 volts) than the first DC electric power 126 (e.g., 200 volts).

[0059] refer to Figure 2 and Figure 3, a schematic diagram of an example implementation of a charging socket 92 is shown according to one or more exemplary embodiments. The charging socket 92 includes a plurality of communication conductors 84a-84n for communication signals 84, four socket conductors 94, and a plurality of control connectors 80a-80d for control signals 80. The four socket conductors 94 include a first line L1, a second line L2, a third line L3, and a neutral line N. The communication conductors 84a-84n are connected to the controller 140. The four socket conductors 94 can be connected to the power factor correction circuit 110 and the controller 140. The control connectors 80a-80d are connected to the controller 140.

[0060] The communication signals 84 may conform to the SAE International J1772 standard and / or the International Electrotechnical Commission (IEC) 61851-1 standard. The communication signals 84 may be transmitted via communication conductors 84a-84n.

[0061] In the three-phase input mode and the three-phase output mode, the first line L1, the second line L2 and the third line L3 of the four socket conductors 94 correspond to the respective active phases of the three-phase electrical signal 78. The neutral line N corresponds to the return line. In the single-phase input mode and the single-phase output mode, the first line L1 and the second line L2 are operated in parallel as active phase inputs. The third line L3 and the neutral line N are operated in parallel as return lines. The changes of the lines L1, L2, L3 and N may include using the first line L1 and the third line L3 as active phases and using the second line L2 and the neutral line N as return lines, or using the second line L2 and the third line L3 as active phases and using the first line L1 and the neutral line N as return lines.

[0062] The control connectors 80a-80d may provide coded signals to inform the controller 140 that a particular mode of a plurality (e.g., four) of operating modes should be executed. For example, the control conductors 80a-80c may correspond to bits A, B, and C, with the control conductor 80d being ground. Bits A, B, and C may default to ground (e.g., logical 0). The charging station 72 or any other device connected to the charging receptacle 92 may indicate the number of phases and direction by pulling two or more of bits A, B, and C high (e.g., logical 1). Bits A, B, and C may indicate a mode according to Table I, as follows:

[0063] Table I

[0064] A B C Order 0 0 0 No connection 0 0 1 mistake 0 1 0 mistake 0 1 1 Single-phase input 1 0 0 mistake 1 0 1 Three-phase input 1 1 0 Single-phase output 1 1 1 Three-phase output

[0065] Other numbers of bits and / or other bit sequences may be implemented to meet the design criteria of a particular application.

[0066] refer to Figure 4, according to one or more exemplary embodiments, a schematic diagram of an example implementation of a power factor correction circuit 110 and a DC to DC converter 150 is shown. The power factor correction circuit 110 generally includes an electrical interface 112, a plurality of inductors 116, a first power bus 120, a second power bus 122, a plurality of first transistors (Q1, Q3, Q5, and Q7), a plurality of second transistors (Q2, Q4, Q6, and Q8), and a capacitor Ca. A first DC electric power 126 is established between the first power bus 120 and the second power bus 122.

[0067] The electrical interface 112 includes a plurality of (e.g., four) interface conductors 114 (or bus bars). One of the interface conductors 114 is respectively connected to the first line L1, the second line L2, the third line L3, and the neutral line N in the charging socket 92. The interface conductor 114 transmits current 118. Compared to a conventional power factor correction circuit that relies only on the neutral line N to carry current, the use of two pairs of interface conductors 114 operating in parallel when in single-phase input mode generally allows for the implementation of smaller conductors.

[0068] Inductors 116 are connected in series to corresponding interface conductors of four interface conductors 114. Inductors 116 are operable to store energy during half of each cycle of the active phase and release energy during the other half of the cycle. A specific inductor 116n among the inductors 116 is connected in series in the neutral line N. When operating in single-phase input mode, the specific inductor 116n can operate in parallel with one of the other inductors 116 on line L1, L2 or L3. Compared with ordinary power factor correction circuits that do not include a specific inductor 116n on the neutral line N, the use of two pairs of inductors 116 operating in parallel when in single-phase input mode generally allows the implementation of smaller inductors. In three-phase input mode, three of the inductors 116 can be used.

[0069] The first transistors Q1, Q3, Q5, and Q7 couple respective ones of the inductors 116 to the first power bus 120. The first transistors Q1, Q3, Q5, and Q7 are each controlled by a switching component of the switching signal 128.

[0070] The second transistors Q2, Q4, Q6 and Q8 couple the corresponding inductors in the inductor 116 to the second power bus 122. The second transistors Q2, Q4, Q6 and Q8 are each controlled by a switching component of the switching signal 128. The switches Q1-Q8 may be MOSFETs, IGBTs, HEMTs, etc., including wide bandgap semiconductors such as silicon carbide and gallium nitrate. Compared to ordinary power factor correction circuits that rely solely on the neutral line N to carry current, the use of two pairs of transistors Q1-Q8 operating in parallel when in single-phase input mode generally allows smaller transistors to be implemented.

[0071] Capacitor Ca is connected between the first power bus 120 and the second power bus 122. Capacitor Ca is operable to store energy during half of each cycle of the active phase (e.g., when the inductor 116 is discharging energy) and to release energy during the other half of the cycle (e.g., when the inductor 116 is storing energy).

[0072] The DC-to-DC converter 150 generally includes a third power bus 156, a fourth power bus 158, a fifth power bus 160, a sixth power bus 162, a transformer having a first winding Lr1 and a second winding Lr2, a capacitor Cr1, a capacitor Cr2, a capacitor Cb, and a plurality of third transistors (e.g., Q9 to Q16). The third transistors Q9 to Q16 are controlled by the controller 140 (see Figure 2 ) is controlled via the respective components of the DC conversion signal 142. The second DC electric power 154 is established between the fifth power bus 160 and the sixth power bus 162.

[0073] The third power bus 156 is connected to the first winding Lr1 through third transistors Q9 and Q11. The third power bus 156 is also connected to the first power bus 120 at the first DC electrical interface 124.

[0074] The fourth power bus 158 is connected to the first winding Lr1 through the capacitor Cr1 and the third transistors Q10 and Q12. The fourth power bus 158 is also connected to the second power bus 122 at the first DC electrical interface 124.

[0075] The fifth power bus 160 is connected to the second winding Lr2 through the third transistors Q13 and Q15. The fifth power bus 160 is also connected to the battery pack 98 at the second DC electrical interface 152 (see Figure 1 ).

[0076] The sixth power bus 162 is connected to the second winding Lr2 through the capacitor Cr2 and the third transistors Q14 and Q16. The sixth power bus 162 is also connected to the battery pack 98 at the second DC electrical interface 152 (see Figure 1 ). The switches Q9-Q18 may be MOSFETs, IGBTs, HEMTs, etc., including wide bandgap semiconductors such as silicon carbide and gallium nitrate.

[0077] refer to Figure 5, according to one or more exemplary embodiments, a schematic diagram of an example inductor charging in a single-phase input mode is shown. The input single-phase electric power 170 generally has a sinusoidal voltage. When the input single-phase electric power 170 causes the current 118 flowing through the inductor 116 to rise, and the amplitude of the voltage of the active phase 172 relative to the return phase 174 is greater than zero volts, the controller 140 turns on the second transistors Q2, Q4, Q6 and Q8, and turns off the first transistors Q1, Q3, Q5 and Q7. The active second transistors Q2, Q4, Q6 and Q8 allow the current 118 to establish a magnetic field around the inductor 116, thereby storing energy. At the same time, the capacitor Ca discharges to provide the first DC electric power 126 to the DC to DC converter 150.

[0078] refer to Figure 6 , according to one or more exemplary embodiments, a schematic diagram of an example inductor discharge in a single-phase input mode is shown. When the input single-phase electric power 170 causes the current 118 flowing through the inductor 116 to drop and the amplitude of the voltage of the active phase 172 relative to the return phase 174 is greater than zero volts, the controller 140 turns on two of the first transistors (e.g., Q1 and Q3) and two of the second transistors (e.g., Q6 and Q8). The remaining transistors (e.g., Q2, Q3, Q4, and Q5) are turned off. The active first transistors Q1 and Q3 and the active second transistors Q6 and Q8 allow the magnetic field around the inductor 116 to collapse, thereby providing the first DC electric power 126 to the DC to DC converter 150. At the same time, the capacitor Ca is charged by the first DC electric power 126.

[0079] refer to Figure 7 , according to one or more exemplary embodiments, a schematic diagram of an example inductor charging in a single-phase input mode is shown. When the input single-phase electric power 170 causes the current 118 flowing through the inductor 116 to rise, and the amplitude of the voltage of the active phase 172 relative to the return phase 174 is less than zero volts, the controller 140 turns on the second transistors Q2, Q4, Q6 and Q8, and turns off the first transistors Q1, Q3, Q5 and Q7. The active second transistors Q2, Q4, Q6 and Q8 allow the current 118 to establish a magnetic field around the inductor 116, thereby storing energy. At the same time, the capacitor Ca is discharged to provide the first DC electric power 126 to the DC to DC converter 150.

[0080] refer to Figure 8, according to one or more exemplary embodiments, a schematic diagram of an example inductor discharge in a single-phase input mode is shown. When the input single-phase electric power 170 causes the current 118 flowing through the inductor 116 to drop, and the amplitude of the voltage of the active phase 172 relative to the return phase 174 is less than zero volts, the controller 140 turns on two of the first transistors (e.g., Q5 and Q7) and two of the second transistors (e.g., Q2 and Q4). The remaining transistors (e.g., Q1, Q3, Q6, and Q8) are turned off. The active first transistors Q5 and Q7 and the active second transistors Q2 and Q4 allow the magnetic field around the inductor 116 to collapse, thereby providing the first DC electric power 126 to the DC to DC converter 150. At the same time, the capacitor Ca is charged by the first DC electric power 126.

[0081] refer to Fig. 9 , according to one or more exemplary embodiments, a schematic diagram of an example inductor charging in a three-phase input mode is shown. Consider only the third line L3. The input three-phase electric power 180 typically has a sinusoidal voltage on each active phase. The three active phase voltages can be 120 degrees apart from each other. When the input three-phase electric power 180 causes the current 118 flowing through the inductor 116 in the third line L3 to rise and the amplitude of the voltage of the corresponding active phase (e.g., 186) relative to the return phase 188 is greater than zero volts, the controller 140 turns on the first transistor Q6. The active first transistor Q6 allows the current 118 to establish a magnetic field around the corresponding inductor 116, thereby storing energy. At the same time, the capacitor Ca discharges to provide the first DC electric power 126 to the DC to DC converter 150. At other times, similar inductor charging occurs on the first line L1 and the second line L2.

[0082] refer to Fig.10 , according to one or more exemplary embodiments, a schematic diagram of an example inductor discharge in a three-phase input mode is shown. Consider only the third line L3. When the input three-phase electric power 180 causes the current 118 flowing through the inductor 116 in the third line L3 to drop and the amplitude of the voltage of the corresponding active phase 186 relative to the return phase 188 is greater than zero volts, the controller 140 turns on the first transistor Q8 and the second transistor Q5. The active second transistor Q5 and the first transistor Q8 allow the magnetic field around the corresponding inductor 116 to collapse, thereby providing the first DC electric power 126 to the DC to DC converter 150. At the same time, the capacitor Ca is charged by the first DC electric power 126. At other times, similar inductor discharges occur on the first line L1 and the second line L2.

[0083] refer to Figure 1 , Figure 2 and Fig.11, a flow chart of an example method 220 for power conversion is shown according to one or more exemplary embodiments. The method (or process) 220 is implemented by the power converter 100. The method 220 includes steps 222 to 232, as shown. The order of steps is shown as a representative example. Other step orders can be implemented to meet the criteria of a specific application.

[0084] In step 222, the controller 140 receives a control signal 80 indicating the direction and number of phases of the electric power 78. The controller 140 then configures the power factor correction circuit 110 and the DC-to-DC converter 150 in step 224 based on the data received in the control signal 80. The controller 140 may signal the charging station 72 via the communication signal 84 in step 226 to begin transmitting power. When the power converter 100 is operating in a single-phase input mode or a three-phase input mode, the power converter 100 receives AC electric power 78 from the charging station 72. When the power converter 100 is operating in a single-phase output mode or a three-phase output mode, the power converter 100 provides AC electric power 78 at the charging receptacle 92 in step 230. Once the power transfer is complete, the controller 140 may signal the stop of the transfer in step 232 via the communication signal 84.

[0085] refer to Figure 1 , Figure 2 and Fig.12 , according to one or more exemplary embodiments, a flow chart of an example method 228a for receiving single-phase electrical power 78 is shown. The method (or process) 228a implements step 228 in method 220. The method 228a includes steps 240 to 248, as shown. The order of steps is shown as a representative example. Other order of steps can be implemented to meet the criteria of a specific application.

[0086] In step 240, the power factor correction circuit 110 receives the electric power 78 through the four socket conductors 94 of the electrical interface 112. The controller 140 generates a switching signal 128 in step 242 to control the power factor correction circuit 110 to operate in the single-phase input mode in response to a first command (e.g., single-phase input mode) received via the control signal 80. In step 244, in the power factor correction circuit 110 operating in the single-phase input mode, the power factor correction circuit 110 converts the input single-phase electric power 78 into a first DC electric power 126. In step 246, the DC-to-DC converter 150 converts (e.g., step-up conversion) the first DC electric power 126 into a second DC electric power 154. The second DC electric power 154 charges the battery pack 98 in step 248.

[0087] refer to Figure 1 , Figure 2 and Fig.13, according to one or more exemplary embodiments, a flow chart of an example method 228b for receiving three-phase electrical power 78 is shown. The method (or process) 228b implements step 228 in method 220. The method 228b includes steps 240, 250, 252, 246, and 248, as shown. The order of steps is shown as a representative example. Other order of steps can be implemented to meet the criteria of a specific application.

[0088] In step 240, the power factor correction circuit 110 receives the electrical power 78 through the four socket conductors 94 of the electrical interface 112. In step 250, the controller 140 generates a switching signal 128 in response to a second command received via the control signal 80 to control the power factor correction circuit 110 to operate in the three-phase input mode. When the power factor correction circuit 110 operates in the three-phase input mode, the input three-phase electrical power is converted into a first DC electrical power 126 in step 252. In step 246, the DC-to-DC converter 150 converts (e.g., boosts) the first DC electrical power 126 into a second DC electrical power 154. The second DC electrical power 154 charges the battery pack 98 in step 248.

[0089] refer to Figure 1 , Figure 2 and Fig.14 , according to one or more exemplary embodiments, a flow chart of an example method 230a for providing single-phase electrical power 78 is shown. The method (or process) 230a implements step 230 in method 220. The method 230a includes steps 260 to 268, as shown. The order of steps is shown as a representative example. Other order of steps can be implemented to meet the criteria of a specific application.

[0090] In step 260, the DC-to-DC converter 150 draws the second DC electric power 154 from the battery pack 98. The DC-to-DC converter 150 then converts (e.g., steps down) the second DC electric power 154 to the first DC electric power 126 in step 262. In step 264, the controller 140 controls the power factor correction circuit 110 to operate in the single-phase input mode in response to a third command received via the control signal 80. When the power factor correction circuit 110 operates in the single-phase output mode, the first DC electric power 126 is converted into the output single-phase electric power 78 in step 266. In step 268, the output single-phase electric power 78 is provided at the electrical interface 112 and the charging receptacle 92.

[0091] refer to Figure 1 , Figure 2 and Fig.15, according to one or more exemplary embodiments, a flow chart of an example of a method 230b for providing three-phase electrical power 78 is shown. The method (or process) 230b implements step 230 in method 220. The method 230b includes steps 260, 262, and 270 to 274, as shown. The order of steps is shown as a representative example. Other order of steps can be implemented to meet the criteria of a specific application.

[0092] In step 260, the DC-to-DC converter 150 draws the second DC electric power 154 from the battery pack 98. The DC-to-DC converter 150 then converts (e.g., steps down) the second DC electric power 154 to the first DC electric power 126 in step 262. In step 270, the controller 140 controls the power factor correction circuit 110 to operate in a three-phase output mode in response to a fourth command received via the control signal 80. When the power factor correction circuit 110 operates in the three-phase output mode, the first DC electric power 126 is converted into an output three-phase electric power 78 in step 272. In step 274, the output three-phase electric power 78 is provided at the electrical interface 112 and the charging receptacle 92.

[0093] Embodiments of the power converter 100 can generally reduce the size of components to support lower power standards through each component, which can reduce component costs and improve system efficiency by reducing heat generation and other losses. In addition, redundancy within the power factor correction circuit 110 can improve functional safety, performance, fault tolerance, etc.

[0094] Redundancy in single-phase mode is typically achieved by an inductor 116n on the neutral line N. If one of the input lines and / or one of the return lines fails (e.g., becomes open), the second line (on the input line and / or the return line) may take on the entire load. Figure 5 As shown, in the case where the line L3 and the neutral line N are used as return lines, if the third line L3 becomes open circuit, the neutral line N is still used as the return path. If the neutral line N experiences an open circuit, the third line L3 is still used as the return path. Similarly, if the first line L1 experiences an open circuit, the second line L2 is still used as the input path. If the second line L2 becomes open circuit, the first line L1 is still used as the input path. The transmitted power may be reduced to solve the problem of line loss, or the size of the components may be designed to carry all single-phase loads.

[0095] Redundancy in three-phase mode is achieved by the ability to accept power through lines L1, L2, and L3 without involving the neutral line N. For example, if the neutral line N is no longer available (e.g., a three-phase delta configuration), two of the input phases (e.g., on the first line L1 and the second line L2) can utilize another phase (e.g., the third line L3) as a return path.

[0096] One of ordinary skill in the art will recognize that terms such as "above," "below," "front," "back," "upward," "downward," "top," "bottom," and the like may be used descriptively herein without limiting the scope of the present disclosure. Furthermore, the present teachings may be described in terms of functional and / or logical block components and / or various processing steps. Such block components may be comprised of various hardware components, software components executed on hardware, and / or firmware components executed on hardware.

[0097] The foregoing detailed description and drawings support and describe the present disclosure, but the scope of the present disclosure is limited only by the claims. As will be appreciated by those skilled in the art, there are various alternative designs and embodiments to practice the disclosure defined in the appended claims.

Claims

1. A power converter, which comprises: a power factor correction circuit having an electrical interface with four interface conductors, the power factor correction circuit being configured to: when operating in single-phase input mode, convert the input single-phase electrical power into a first DC electrical power, wherein the active phase of the input single-phase electrical power is received in parallel through the first conductor and the second conductor among the four interface conductors; and the return phase of the input single-phase electrical power is received in parallel through the third conductor and the fourth conductor among the four interface conductors; and when operating in three-phase input mode, convert the input three-phase electrical power into the first DC electrical power; wherein the first phase of the input three-phase electrical power is received through the first conductor among the four interface conductors; the second phase of the input three-phase electrical power is received through the second conductor among the four interface conductors; the third phase of the input three-phase electrical power is received through the third conductor among the four interface conductors; and the return phase of the input three-phase electrical power is received through the fourth conductor among the four interface conductors; and a controller configured to control the power factor correction circuit to: operate in the single-phase input mode in response to a first command received via a control signal; and operate in the three-phase input mode in response to a second command received via the control signal.

2. The power converter according to claim 1, wherein the power factor correction circuit comprises: four inductors respectively connected in series with the four interface conductors, wherein the four interface conductors are configured to transmit four currents; a plurality of first transistors controlled by the controller to selectively switch the four inductors to a first power bus; and a plurality of second transistors controlled by the controller to selectively switch the four inductors to a second power bus, wherein the first DC electrical power is established between the first power bus and the second power bus.

3. The power converter according to claim 2, wherein when in the single-phase input mode, in response to the voltage of the active phase being greater than zero volts relative to the return phase and the four amplitudes of the four currents in the four inductors being rising, the plurality of second transistors switch the four inductors to the second power bus.

4. The power converter according to claim 3, wherein: when in the single-phase input mode, in response to the voltage of the active phase being greater than zero volts relative to the return phase and the four amplitudes of the four currents in the four inductors being falling, the plurality of first transistors switch two of the four inductors to the first power bus; and When in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, the plurality of second transistors switch two of the four inductors to the second power bus.

5. The power converter according to claim 3, wherein when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being increasing, the plurality of second transistors switch the four inductors to the second power bus.

6. The power converter according to claim 5, wherein: when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, the plurality of first transistors switch two of the four inductors to the first power bus; and when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, the plurality of second transistors switch two of the four inductors to the second power bus.

7. The power converter according to claim 1, further comprising: a DC-DC converter configured to convert the first DC electrical power into a second DC electrical power, wherein the second DC electrical power has a voltage different from that of the first DC electrical power.

8. The power converter according to claim 1, wherein: the power factor correction circuit is further configured to: when operating in the single-phase output mode, convert the first DC electrical power into an output single-phase electrical power; provide the output single-phase electrical power at the electrical interface; when operating in the three-phase output mode, convert the first DC electrical power into an output three-phase electrical power; and provide the output three-phase electrical power at the electrical interface; and the controller is further configured to control the power factor correction circuit to: operate in the single-phase output mode in response to a third command received via the control signal; and operate in the three-phase output mode in response to a fourth command received via the control signal.

9. The power converter according to claim 1, wherein the power factor correction circuit and the controller are implemented in a vehicle.

10. A method for power conversion, comprising: receiving electrical power through four interface conductors of an electrical interface of a power factor correction circuit; in the power factor correction circuit operating in the single-phase input mode, converting the input single-phase electrical power into a first DC electrical power, wherein the active phase of the input single-phase electrical power is received in parallel through a first conductor and a second conductor of the four interface conductors; and the return phase of the input single-phase electrical power is received in parallel through a third conductor and a fourth conductor of the four interface conductors; In the power factor correction circuit operating in a three-phase input mode, an input three-phase electric power is converted into the first DC electric power, wherein a first phase of the input three-phase electric power is received through the first of the four interface conductors; a second phase of the input three-phase electric power is received through the second of the four interface conductors; a third phase of the input three-phase electric power is received through the third of the four interface conductors; and a return phase of the input three-phase electric power is received through the fourth of the four interface conductors; the power factor correction circuit is controlled by a controller to operate in the single-phase input mode in response to a first command received via a control signal; and the power factor correction circuit is controlled by the controller to operate in the three-phase input mode in response to a second command received via the control signal.

11. The method according to claim 10, wherein the power factor correction circuit comprises: four inductors respectively connected in series with the four interface conductors, wherein the four interface conductors are configured to transmit four currents; a plurality of first transistors controlled by the controller to selectively switch the four inductors to a first power bus; and a plurality of second transistors controlled by the controller to selectively switch the four inductors to a second power bus, wherein the first DC electric power is established between the first power bus and the second power bus.

12. The method according to claim 11, further comprises: when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being rising, switching the four inductors to the second power bus through the plurality of second transistors.

13. The method according to claim 12, further comprises: when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being falling, switching two of the four inductors to the first power bus through the plurality of first transistors; and when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being greater than zero volts and the four amplitudes of the four currents in the four inductors being falling, switching two of the four inductors to the second power bus through the plurality of second transistors.

14. The method according to claim 12, further comprises: when in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being rising, switching the four inductors to the second power bus through the plurality of second transistors.

15. The method according to claim 14, further comprises: When in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, two of the four inductors are switched to the first power bus by the plurality of first transistors; and When in the single-phase input mode, in response to the voltage of the active phase relative to the return phase being less than zero volts and the four amplitudes of the four currents in the four inductors being decreasing, two of the four inductors are switched to the second power bus by the plurality of second transistors.

16. The method according to claim 10, further comprising: Converting the first DC electric power into second DC electric power, wherein the second DC electric power has a voltage different from that of the first DC electric power.

17. The method according to claim 10, further comprising: In the power factor correction circuit operating in the single-phase output mode, converting the first DC electric power into output single-phase electric power; Providing the output single-phase electric power at the electrical interface; In the power factor correction circuit operating in the three-phase output mode, converting the first DC electric power into output three-phase electric power; Providing the output three-phase electric power at the electrical interface; Controlling the power factor correction circuit to operate in the single-phase output mode in response to a third command received via the control signal; and Controlling the power factor correction circuit to operate in the three-phase output mode in response to a fourth command received via the control signal.

18. A vehicle, comprising: A charging socket having at least four socket conductors; A power factor correction circuit electrically connected to the charging socket, the power factor correction circuit being configured to: When operating in the single-phase input mode, convert input single-phase electric power into first DC electric power, wherein The active phase of the input single-phase electric power is received in parallel through a first socket conductor and a second socket conductor among the four socket conductors; and The return phase of the input single-phase electric power is received in parallel through a third socket conductor and a fourth socket conductor among the four socket conductors; and When operating in the three-phase input mode, convert input three-phase electric power into the first DC electric power, wherein The first phase of the input three-phase electric power is received through the first socket conductor among the four socket conductors; The second phase of the input three-phase electric power is received through the second socket conductor among the four socket conductors; The third phase of the input three-phase electric power is received through the third socket conductor among the four socket conductors; and The return phase of the input three-phase electric power is received through the fourth socket conductor among the four socket conductors; and A controller configured to control the power factor correction circuit to: Operate in the single-phase input mode in response to a first command received via a control signal; and Operate in the three-phase input mode in response to a second command received via the control signal.

19. The vehicle according to claim 18, further comprising: A DC-DC converter configured to bidirectionally convert between the first DC electric power and the second DC electric power, wherein the second DC electric power has a voltage different from that of the first DC electric power; and A battery pack electrically connected to the DC-DC converter, the battery pack being configured to receive the second DC electric power from the DC-DC converter when in the charging mode, and being configured to provide the second DC electric power to the DC-DC converter when in the discharging mode.

20. The vehicle according to claim 19, wherein: The power factor correction circuit is further configured to: When operating in the single-phase output mode, convert the first DC electric power into an output single-phase electric power; Provide the output single-phase electric power to the charging socket; When operating in the three-phase output mode, convert the first DC electric power into an output three-phase electric power; and Provide the output three-phase electric power to the charging socket; and The controller is further configured to control the power factor correction circuit to: Operate in the single-phase output mode in response to a third command received via the control signal; and Operate in the three-phase output mode in response to a fourth command received via the control signal.

Images