Power converter for vehicle charging

Abstract

A power converter can include a primary side having a line connection port and a plurality of semiconductor switches, and a secondary side having one or more alternating current (AC) to direct current (DC) converters and one or more load connection ports. The power converter can also include one or more transformers configured to transfer power between the primary side and the secondary side.

Description

Technical Field

[0001] This disclosure relates to apparatus and systems for power conversion in electric vehicles. Background Technology

[0002] To achieve efficient battery charging in electric vehicle (xEV) applications, on-board charging modules (OBCMs) can be used. An OBCM is an integrated power electronic system that typically includes controllable semiconductor switches to perform charging tasks such as AC-to-DC conversion, voltage regulation, and / or similar tasks. In some examples, OBCMs employ a bidirectional design, allowing not only battery charging but also energy feedback to the grid or auxiliary systems. In some examples, OBCMs incorporate thermal management systems to ensure reliable operation under varying environmental conditions, such as extreme temperatures. Furthermore, OBCMs may include a communication interface for interacting with external charging stations, enabling power adjustment and optimized charging configuration based on battery health and charging status.

[0003] Although the devices and systems used for power conversion have achieved their intended purpose, a new and improved power converter for charging electric vehicles is still needed. Summary of the Invention

[0004] According to several aspects, a power converter is provided. The power converter may include a primary side having line connection ports and a plurality of semiconductor switches, and a secondary side having one or more AC-to-DC converters and one or more load connection ports. The power converter may also include one or more transformers configured to deliver power between the primary and secondary sides.

[0005] In another aspect of this disclosure, the line connection port may include two or more of the following: a first AC phase connection, a second AC phase connection, a third AC phase connection, and a neutral AC connection. The line connection port may also include multiple electrically controlled switches that are in electrical communication with the first AC connection, the second AC connection, the third AC connection, and the neutral AC connection.

[0006] In another aspect of this disclosure, the plurality of semiconductor switches may further include one or more switch pairs. A first switch of each of the one or more switch pairs is connected between a first terminal of a first primary winding of one or more primary windings of one or more transformers and a common node of the switch pair. A second switch of each of the one or more switch pairs is connected between a second terminal of a first primary winding of one or more primary windings of one or more transformers and the common node of the switch pair. The common node of the switch pair is in electrical communication with a line connection port.

[0007] In another aspect of this disclosure, one or more switch pairs may further include a first switch pair connected between a first terminal and a second terminal of the first primary winding, and having a first switch pair common node in electrical communication with a first AC connection. One or more switch pairs may further include a second switch pair connected between the first and second terminals of the first primary winding, and having a second switch pair common node in electrical communication with a second AC connection. One or more switch pairs may further include a third switch pair connected between the first and second terminals of the first primary winding, and having a third switch pair common node in electrical communication with a third AC connection. One or more switch pairs may further include a fourth switch pair connected between the first and second terminals of the first primary winding, and having a fourth switch pair common node in electrical communication with a neutral AC connection.

[0008] In another aspect of this disclosure, the plurality of electrical control switches may further include a first electrical control switch connected between the first AC phase connection and the first switch pair common node. The plurality of electrical control switches may further include a second electrical control switch connected between the second AC phase connection and the second switch pair common node. The plurality of electrical control switches may further include a third electrical control switch connected between the third AC phase connection and the third switch pair common node. The plurality of electrical control switches may further include a fourth electrical control switch connected between the neutral AC connection and the fourth switch pair common node. The plurality of electrical control switches may further include a fifth electrical control switch connected between the first switch pair common node and the second switch pair common node. The plurality of electrical control switches may further include a sixth electrical control switch connected between the third switch pair common node and the fourth switch pair common node.

[0009] In another aspect of this disclosure, one or more switch pairs may further include a first switch pair connected between a first terminal and a second terminal of a first primary winding, and having a first switch pair common node in electrical communication with a first AC connection. One or more switch pairs may further include a second switch pair connected between a first terminal and a second terminal of a first primary winding, and having a second switch pair common node in electrical communication with a neutral AC connection. One or more switch pairs may further include a third switch pair connected between a first terminal and a second terminal of a second primary winding of one or more primary windings of one or more transformers, and having a third switch pair common node in electrical communication with a second AC connection. One or more switch pairs may further include a fourth switch pair connected between a first terminal and a second terminal of a second primary winding of one or more primary windings, and having a fourth switch pair common node in electrical communication with a neutral AC connection. One or more switch pairs may further include a fifth switch pair connected between a first terminal and a second terminal of a third primary winding of one or more primary windings of one or more transformers, and having a fifth switch pair common node in electrical communication with a third AC connection. One or more switch pairs may also include a sixth switch pair connected between the first terminal of the third primary winding and the second terminal of the third primary winding, and having a sixth switch pair common node in communication with the neutral AC connection.

[0010] In another aspect of this disclosure, the plurality of electrical control switches may further include a first electrical control switch connected between the first AC phase connection and the first switch pair common node. The plurality of electrical control switches may further include a second electrical control switch connected between the second AC phase connection and the third switch pair common node. The plurality of electrical control switches may further include a third electrical control switch connected between the third AC phase connection and the fifth switch pair common node. The plurality of electrical control switches may further include a fourth electrical control switch connected between the first switch pair common node and the third switch pair common node. The plurality of electrical control switches may further include a fifth electrical control switch connected between the first switch pair common node and the fifth switch pair common node. The plurality of electrical control switches may further include a sixth electrical control switch connected between the neutral AC connection and the second switch pair common node, the fourth switch pair common node, and the sixth switch pair common node.

[0011] In another aspect of this disclosure, one or more secondary AC-to-DC converters may further include one or more active full-wave rectifiers. The AC side of each of the one or more active full-wave rectifiers is connected to one or more secondary windings of one or more transformers. The DC side of each of the one or more active full-wave rectifiers is connected in parallel to one or more DC loads connected to one or more load connection ports.

[0012] In another aspect of this disclosure, the secondary side may further include one or more AC-to-AC converters. A first side of each of the one or more AC-to-AC converters is connected to one or more secondary windings of one or more transformers. A second side of each of the one or more AC-to-AC converters is connected to one or more AC load connections at one or more load connection ports.

[0013] In another aspect of this disclosure, one or more AC-to-AC converters may further include one or more switch pairs. A first switch of each of the one or more switch pairs is connected between a first terminal of one or more AC load connections and a common node of the switch pair. A second switch of each of the one or more switch pairs is connected between a second terminal of one or more AC load connections and a common node of the switch pair. The common node of the switch pair is in electrical communication with one or more secondary windings of one or more transformers.

[0014] According to several aspects, a power converter for a vehicle is provided. The power converter may include a primary side having a line connection port and one or more primary AC-to-AC converters. The line connection port may further include a first AC phase connection, a second AC phase connection, a third AC phase connection, a neutral AC connection, and a plurality of electrically controlled switches in electrical communication with the first AC connection, the second AC connection, the third AC connection, and the neutral AC connection. The power converter may further include a secondary side having one or more secondary AC-to-DC converters and one or more load connection ports. At least one of the one or more load connection ports is in electrical communication with the vehicle's battery. The power converter may also include a transformer configured to deliver power between the primary side and the secondary side.

[0015] In another aspect of this disclosure, one or more primary AC-to-AC converters may further include a single primary AC-to-AC converter having four single-converter line ports and two single-converter load ports. A first single-converter line port of the four single-converter line ports is connected to a first AC phase connection. A second single-converter line port of the four single-converter line ports is connected to a second AC phase connection. A third single-converter line port of the four single-converter line ports is connected to a third AC phase connection. A fourth single-converter line port of the four single-converter line ports is connected to a neutral AC connection. The two single-converter load ports are connected to one or more primary windings of the transformer.

[0016] In another aspect of this disclosure, a first single-converter line port of the four single-converter line ports is connected to a first AC phase connection via a first electrical control switch of a plurality of electrical control switches. A second single-converter line port of the four single-converter line ports is connected to a second AC phase connection via a second electrical control switch of a plurality of electrical control switches. A third single-converter line port of the four single-converter line ports is connected to a third AC phase connection via a third electrical control switch of a plurality of electrical control switches. A fourth single-converter line port of the four single-converter line ports is connected to a neutral AC connection via a fourth electrical control switch of a plurality of electrical control switches. A fifth single-converter line port of the plurality of electrical control switches is connected between the first single-converter line port and the second single-converter line port of the four single-converter line ports. A sixth electrical control switch of the plurality of electrical control switches is connected between the third single-converter line port and the fourth single-converter line port of the four single-converter line ports.

[0017] In another aspect of this disclosure, one or more primary AC-to-AC converters may further include a first primary AC-to-AC converter having two first converter line ports and two first converter load ports. The first of the two first converter line ports is connected to a first AC phase connection. The second of the two first converter line ports is connected to a neutral AC connection. The two first converter load ports are connected to one or more primary windings of a transformer. A second primary AC-to-AC converter has two second converter line ports and two second converter load ports. The first of the two second converter line ports is connected to a second AC phase connection. The second of the two second converter line ports is connected to a neutral AC connection. The two second converter load ports are connected to one or more primary windings of a transformer. A third primary AC-to-AC converter has two third converter line ports and two third converter load ports. The first of the two third converter line ports is connected to a third AC phase connection. The second of the two third converter line ports is connected to a neutral AC connection. The two third converter load ports are connected to one or more primary windings of a transformer.

[0018] In another aspect of this disclosure, a first single-converter line port of the four single-converter line ports is connected to a first AC phase connection via a first electrical control switch of a plurality of electrical control switches. A second single-converter line port of the four single-converter line ports is connected to a second AC phase connection via a second electrical control switch of a plurality of electrical control switches. A third single-converter line port of the four single-converter line ports is connected to a third AC phase connection via a third electrical control switch of a plurality of electrical control switches. A fourth single-converter line port of the four single-converter line ports is connected to a neutral AC connection via a fourth electrical control switch of a plurality of electrical control switches. A fifth electrical control switch of a plurality of electrical control switches is connected between the first single-converter line port and the second single-converter line port of the four single-converter line ports. A sixth electrical control switch of a plurality of electrical control switches is connected between the third single-converter line port and the fourth single-converter line port of the four single-converter line ports.

[0019] In another aspect of this disclosure, one or more AC-to-DC converters may further include one or more rectifiers. The AC side of each of the one or more rectifiers is connected to one or more secondary windings of a transformer. The DC side of each of the one or more rectifiers is connected to one or more DC load connections at one or more load connection ports.

[0020] In another aspect of this disclosure, the secondary side may further include one or more AC-to-AC converters. A first side of each of the one or more AC-to-AC converters is connected to one or more secondary windings of the transformer. A second side of each of the one or more AC-to-AC converters is connected to one or more AC load connections at one or more load connection ports. The one or more AC load connections are in electrical communication with one or more external AC loads or power supplies.

[0021] According to several aspects, an on-board charging module (OBCM) for a vehicle is provided. The OBCM may include a primary side having a line connection port and a plurality of bidirectional semiconductor switches. The line connection port may further include a first AC phase connection, a second AC phase connection, a third AC phase connection, a neutral AC connection, and a plurality of electronically controlled switches electrically communicating with the first AC phase connection, the second AC phase connection, the third AC phase connection, and the neutral AC connection. The plurality of bidirectional semiconductor switches include one or more bidirectional switch pairs. The one or more bidirectional switch pairs may further include a first bidirectional switch pair having a first switch pair common node electrically communicating with the first AC phase connection. The one or more bidirectional switch pairs may further include a second bidirectional switch pair having a second switch pair common node electrically communicating with the second AC phase connection. The one or more bidirectional switch pairs may further include a third bidirectional switch pair having a third switch pair common node electrically communicating with the third AC phase connection. The one or more bidirectional switch pairs may further include a fourth bidirectional switch pair having a fourth switch pair common node electrically communicating with the neutral AC connection. The OBCM may also include a secondary side having one or more AC-to-DC converters, one or more AC-to-AC converters, and one or more load connection ports. At least one of the one or more load connection ports is in electrical communication with the vehicle's battery. At least one of the one or more load connection ports is configured to provide a high-voltage DC output. At least one of the one or more load connection ports is configured to provide a low-voltage DC output. At least one of the one or more load connection ports is configured to provide one or more AC outputs. The OBCM may also include a transformer configured to deliver power between the primary and secondary sides. The transformer may include one or more magnetic cores, one or more primary windings, and one or more secondary windings. One of the one or more primary windings is in electrical communication with each of one or more bidirectional switch pairs.

[0022] In another aspect of this disclosure, the plurality of electrical control switches may further include a first electrical control switch connected between the first AC phase connection and the first switch pair common node. The plurality of electrical control switches may further include a second electrical control switch connected between the second AC phase connection and the second switch pair common node. The plurality of electrical control switches may further include a third electrical control switch connected between the third AC phase connection and the third switch pair common node. The plurality of electrical control switches may further include a fourth electrical control switch connected between the neutral AC connection and the fourth switch pair common node. The plurality of electrical control switches may further include a fifth electrical control switch connected between the first switch pair common node and the second switch pair common node. The plurality of electrical control switches may further include a sixth electrical control switch connected between the third switch pair common node and the fourth switch pair common node.

[0023] In another aspect of this disclosure, the OBCM may also include a controller that is electrically communicating with each of the plurality of electrically controlled switches. To configure the OBCM for a single-phase line connection, the controller is programmed to close the first electrically controlled switch, open the second electrically controlled switch, open the third electrically controlled switch, close the fourth electrically controlled switch, close the fifth electrically controlled switch, and close the sixth electrically controlled switch. To configure the OBCM for a three-phase line connection, the controller is also programmed to close the first electrically controlled switch, close the second electrically controlled switch, close the third electrically controlled switch, close the fourth electrically controlled switch, open the fifth electrically controlled switch, and open the sixth electrically controlled switch.

[0024] Further applicability will become apparent from the description provided herein. It should be understood that the descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0025] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0026] Figure 1 This is a schematic diagram of a power converter according to an exemplary embodiment;

[0027] Figure 2 yes Figure 1 A schematic diagram of a first exemplary embodiment of the primary side of a power converter;

[0028] Figure 3 yes Figure 1 A schematic diagram of a second exemplary embodiment of the power converter's primary side;

[0029] Figure 4 yes Figure 1 A schematic diagram of a third exemplary embodiment of the primary side of the power converter;

[0030] Figure 5A This is according to an exemplary embodiment. Figure 1 A schematic diagram of an exemplary embodiment of the secondary side of a power converter;

[0031] Figure 5B This is according to an exemplary embodiment. Figure 5A A continuation of the schematic diagram; and

[0032] Figure 6 This is a schematic diagram of an exemplary embodiment of a power converter according to an exemplary embodiment. Detailed Implementation

[0033] The following description is merely illustrative in nature and is not intended to limit the content, application, or purpose of this disclosure.

[0034] refer to Figure 1A power converter, generally indicated by reference numeral 10, is shown. In this disclosure, the power converter 10 is discussed in the context of vehicle applications, more specifically, in the context of electric vehicle charging applications, and even more specifically, three functions are discussed: electric vehicle charging, vehicle-to-load (V2L) functionality, and auxiliary load power support. In this disclosure, the power converter 10 is also referred to as an on-board charging module (OBCM) or integrated power electronics. Therefore, the power converter 10 is shown in conjunction with an exemplary vehicle 12. Although a passenger vehicle is shown, it should be understood that the vehicle 12 can be any type of vehicle without departing from the scope of this disclosure. It should also be understood that this disclosure is applicable to power converters with a variety of other applications and uses. The power converter 10 generally includes a controller 14, a primary side 16a, a secondary side 16b, and a transformer 16c.

[0035] Controller 14 controls power converter 10 as described below. Controller 14 includes at least one processor 20 and a non-transitory computer-readable storage device or medium 22. Processor 20 may be a custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors associated with controller 14, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, a combination thereof, or generally a device for executing instructions. In an exemplary embodiment, controller 14 controls the operation of primary side 16a and secondary side 16b, as will be discussed in more detail below.

[0036] Computer-readable storage device or medium 22 may include volatile and non-volatile memory such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory used to store various operational variables when the processor 20 is powered off. Computer-readable storage device or medium 22 may be implemented using PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or another electrical, magnetic, optical, or combined storage device capable of storing data, some of which represents executable instructions. Controller 14 may also include multiple controllers that are electrically in communication with each other.

[0037] Controller 14 communicates electrically with primary side 16a and secondary side 16b. In an exemplary embodiment, electrical communication is established using, for example, a CAN network, a FLEXRAY network, a local area network (e.g., Wi-Fi, Ethernet, etc.), a Serial Peripheral Interface (SPI) network, direct analog communication, etc. It should be understood that various other wired and wireless technologies and communication protocols used for communicating with controller 14 are within the scope of this disclosure. It should also be understood that, within the scope of this disclosure, electrical communication also includes the transfer of power and / or energy between electrical devices (e.g., using wired and / or wireless power transmission technologies).

[0038] Several exemplary embodiments of the primary side 16a will be discussed in detail below. Generally, the primary side 16a includes at least one line connection port 30 and one or more primary AC to AC converters.

[0039] Line connection port 30 includes a first AC phase connection 32a, a second AC phase connection 32b, a third AC connection 32c, a neutral AC connection 32d, and multiple electrically controllable switches. Figures 2-4 Line connection port 30 allows single-phase or three-phase connection to an AC power source, such as an electric vehicle power supply unit (EVSE). Furthermore, line connection port 30 allows the power converter 10 to act as a single-phase or three-phase AC power source, thereby providing AC power to single-phase or three-phase AC loads. In some embodiments, line connection port 30 may include only a first AC phase connection 32a and a neutral AC connection 32d, omitting multiple electrically controlled switches for operation in single-phase mode.

[0040] Multiple electrically controlled switches are used to control the connections between the first AC phase connection 32a, the second AC phase connection 32b, the third AC phase connection 32c, and the neutral AC connection 32d and the remainder of the primary side 16a, to switch the line connection port 30 between single-phase and three-phase operation. In an exemplary embodiment, the multiple electrically controlled switches include a first electrically controlled switch 34a (… Figures 2-4 ), second electrical control switch 34b ( Figures 2-4 ), third electrical control switch 34c ( Figures 2-4 ), fourth electrical control switch 34d ( Figures 2-4 ), Fifth electrical control switch 34e ( Figures 2-4 ) and the sixth electrical control switch 34f ( Figures 2-4 Multiple electrically controlled switches are connected in different ways in different embodiments of the primary side 16a, as described below. Figures 2-4 As shown and described. In one exemplary embodiment, the plurality of electrically controlled switches are implemented using electromechanical relays, solid-state relays, contactors, and / or the like. The plurality of electrically controlled switches are in electrical communication with controller 14.

[0041] Several exemplary embodiments of the secondary side 16b will be discussed in detail below. Generally, the secondary side 16b includes one or more load connection ports 36, one or more AC-to-DC converters, and one or more AC-to-AC converters.

[0042] One or more load connection ports 36 include at least a first DC load connection 36a in electrical communication with the battery 40 of vehicle 12. The one or more load connection ports 36 allow the power converter 10 to supply power to / receive power from one or more DC loads, including, for example, the battery 40, one or more DC power systems of vehicle 12, one or more auxiliary vehicle loads (e.g., 12-volt or 48-volt loads), and / or the like. One or more AC-to-DC converters are used to convert power to supply power to / receive power from one or more DC loads, as will be discussed in more detail below. One or more AC-to-AC converters are used to convert power to supply power to / receive power from one or more AC loads, as will be discussed in more detail below.

[0043] It should be understood that any of the various exemplary embodiments of the primary side 16a can be combined with any of the various exemplary embodiments of the secondary side 16b to form the power converter 10. It should also be understood that the power converter 10 is operable to deliver power bidirectionally, including delivering power from the line connection port 30 to one or more load connection ports 36, or delivering power from one or more load connection ports 36 to the line connection port 30.

[0044] Transformer 16c is used to transmit power between the primary side 16a and the secondary side 16b. In an exemplary embodiment, transformer 16c includes one or more primary windings and one or more secondary windings electromagnetically coupled through a magnetic core. It should be understood that any type of transformer, including, for example, a transformer with a single primary winding and a single secondary winding, a transformer with multiple primary windings and a single secondary winding, a transformer with a single primary winding and multiple secondary windings, or a transformer with multiple primary windings and multiple secondary windings, is within the scope of this disclosure.

[0045] In other words, it should be understood that, without departing from the scope of this disclosure, transformer 16c may include any number of primary windings coupled to any number of secondary windings. Furthermore, transformer 16c may also be implemented using multiple independent transformers or transformers having multiple magnetically coupled or non-magnetically coupled magnetic cores. It should be understood that the winding ratio and number of turns of each primary winding and each secondary winding can be determined based on the desired input / output voltage, operating frequency, etc. Those skilled in the art will understand how to select a suitable transformer based on the primary side 16a and secondary side 16b used to construct the power converter 10.

[0046] refer to Figure 2 The diagram illustrates a first exemplary embodiment of the primary side 16a. Generally, the first exemplary embodiment of the primary side 16a includes a single primary AC-to-AC converter 42a having four single-converter line ports (i.e., a first single-converter line port 44a, a second single-converter line port 44b, a third single-converter line port 44c, and a fourth single-converter line port 44d) and two single-converter load ports (i.e., a first single-converter load port 46a and a second single-converter load port 46b).

[0047] The first single-converter line port 44a is connected to the first AC phase connection 32a via a first electrically controllable switch 34a. The second single-converter line port 44b is connected to the second AC phase connection 32b via a second electrically controlled switch 34b. The third single-converter line port 44c is connected to the third AC phase connection 32c via a third electrically controlled switch 34c. The fourth single-converter line port 44d is connected to the neutral AC connection 32d via a fourth electrically controlled switch 34d. The fifth electrically controlled switch 34e is connected between the first single-converter line port 44a and the second single-converter line port 44b. The sixth electrically controlled switch 34f is connected between the third single-converter line port 44c and the fourth single-converter line port 44d. The first single-converter load port 46a and the second single-converter load port 46b are connected to the first primary winding 56 of the transformer 16c.

[0048] In one exemplary embodiment, the primary side 16a includes one or more switch pairs forming an AC-to-AC converter for a single-phase or three-phase AC line input. In a non-limiting example, the one or more switch pairs include unidirectional semiconductor switches. In another non-limiting example, the one or more switch pairs include bidirectional semiconductor switches forming bidirectional switch pairs. Within the scope of this disclosure, a bidirectional semiconductor switch is a device that can conduct current in both directions when turned on, block voltage in both polarities when turned off, and can be turned on / off using a control signal. Bidirectional semiconductor switches can be implemented in various ways, including, for example, using a three-terminal bidirectional thyristor switch, two anti-parallel thyristors, two anti-parallel or anti-series insulated-gate bipolar transistors (IGBTs), two anti-parallel or anti-series metal-oxide-semiconductor field-effect transistors (MOSFETs), and / or the like.

[0049] For illustrative purposes, in this disclosure, a bidirectional semiconductor switch is shown as a plurality of MOSFETs connected in reverse series. It should be understood that any suitable component or combination of components can be used to implement the bidirectional semiconductor switch without departing from the scope of this disclosure. Furthermore, any suitable semiconductor material (e.g., silicon carbide (SiC), gallium nitride (GaN), etc.) can be used to implement the bidirectional semiconductor switch without departing from the scope of this disclosure.

[0050] Within the scope of this disclosure, a bidirectional switch pair comprises two bidirectional semiconductor switches connected in series. The common node between the two bidirectional semiconductor switches is referred to as the switch pair common node.

[0051] In a first exemplary embodiment of the primary side 16a, one or more bidirectional switch pairs include a first bidirectional switch pair, a second bidirectional switch pair, a third bidirectional switch pair, and a fourth bidirectional switch pair. The first bidirectional switch pair has a first bidirectional switch 52a connected between a first terminal 54a of the first primary winding 56 of one or more primary windings of the transformer 16c and a common node 58a of the first switch pair, and a second bidirectional switch 52b connected between a second terminal 54b of the first primary winding 56 and the common node 58a of the first switch pair, as shown below. Figure 2 As shown. In an exemplary embodiment, if only single-phase operation is required, the third bidirectional switch 52c, the fourth bidirectional switch 52d, the fifth bidirectional switch 52e, the eighth bidirectional switch 52h, the first electrical control switch 34a, the second electrical control switch 34b, the fifth electrical control switch 34e, and the sixth electrical control switch 34f can be omitted.

[0052] The second bidirectional switch pair has a third bidirectional switch 52c connected between the first terminal 54a and the common node 58b of the second switch pair, and a fourth bidirectional switch 52d connected between the second terminal 54b and the common node 58b of the second switch pair, as follows: Figure 2 As shown. The third bidirectional switch pair has a fifth bidirectional switch 52e connected between the first terminal 54a and the common node 58c of the third switch pair, and a sixth bidirectional switch 52f connected between the second terminal 54b and the common node 58c of the third switch pair, as shown. Figure 2 As shown. The fourth bidirectional switch pair has a seventh bidirectional switch 52g connected between the first terminal 54a and the common node 58d of the fourth switch pair, and an eighth bidirectional switch 52h connected between the second terminal 54b and the common node 58d of the fourth switch pair, as shown. Figure 2 As shown.

[0053] In a first exemplary embodiment of the primary side 16a, the first switch pair common node 58a is electrically communicated with the first AC connection 32a via the first electrically controlled switch 34a, such as... Figure 2 As shown. The second switch communicates with the second AC phase 32b via the second electrical control switch 34b to the common node 58b, as shown. Figure 2 As shown. The third switch connects to the common node 58c via the third electrical control switch 34c and the third AC phase 32c for electrical communication, as shown. Figure 2 As shown. The fourth switch communicates electrically with the neutral AC connection 32d via the fourth electrically controlled switch 34d to the common node 58d, as shown. Figure 2 As shown. The fifth electrical control switch 34e is connected between the common node 58a of the first switch pair and the common node 58b of the second switch pair, as follows. Figure 2 As shown. The sixth electrical control switch 34f is connected between the common node 58c of the third switch pair and the common node 58d of the fourth switch pair, as follows. Figure 2 As shown.

[0054] In one exemplary embodiment, controller 14 is programmed to control the operation of the bidirectional switch pair using control terminals (e.g., gate terminals) to provide AC-to-AC power conversion from line connection port 30 to the first primary winding 56 or from the first primary winding 56 to line connection port 30. In a non-limiting example, controller 14 uses interleaved control methods, dual active bridge (DAB) control methods, capacitor-inductor-inductor-capacitor (CLLC) control methods, zero-voltage switching (ZVS) control methods, and / or similar methods to control the operation of the bidirectional switch pair. In a non-limiting example, controller 14 controls the operation of the bidirectional switch pair to provide additional functionality, such as power factor control (PFC).

[0055] In one exemplary embodiment, the controller 14 is programmed to control the operation of a plurality of electrically controlled switches to configure the primary side 16a for single-phase or three-phase operation (i.e., single-phase or three-phase line connection). Table 1 illustrates an exemplary control method for the plurality of electrically controlled switches in a first exemplary embodiment of the primary side 16a:

[0056]

[0057] Table 1

[0058] Wherein: S1 is the first electric control switch 34a, S2 is the second electric control switch 34b, S3 is the third electric control switch 34c, S4 is the fourth electric control switch 34d, S5 is the fifth electric control switch 34e, and S6 is the sixth electric control switch 34f. "Closed" means that the switch conducts current, and "open" means that the switch blocks current.

[0059] refer to Figure 3 A schematic diagram of a second exemplary embodiment of the primary side 16a is shown. Generally, the second exemplary embodiment of the primary side 16a includes a first primary AC-to-AC converter 42b, a second primary AC-to-AC converter 42c, and a third primary AC-to-AC converter 42d. The first primary AC-to-AC converter 42b has two first converter line ports (i.e., a first first converter line port 48a and a second first converter line port 48b) and two first converter load ports (i.e., a first first converter load port 50a and a second first converter load port 50b). The second primary AC-to-AC converter 42c has two second converter line ports (i.e., a first second converter line port 48c and a second second second converter line port 48d) and two second converter load ports (i.e., a first second converter load port 50c and a second second second converter load port 50d). The third primary AC-to-AC converter 42d has two third converter line ports (i.e., a first third converter line port 48e and a second third converter line port 48f) and two third converter load ports (i.e., a first third converter load port 50e and a second third converter load port 50f).

[0060] The first converter line port 48a is connected to the first AC phase connection 32a via a first electrically controllable switch 34a. The first second converter line port 48c is connected to the second AC phase connection 32b via a second electrically controlled switch 34b. The first third converter line port 48e is connected to the third AC phase connection 32c via a third electrically controlled switch 34c. The second first converter line ports 48b, 48d, and 48f are connected to the AC neutral connection 32d via a fifth electrically controlled switch 34f. A fourth electrically controlled switch 34d is connected between the first first converter line port 48a and the first second converter line port 48c. A sixth electrically controlled switch 34e is connected between the first first converter line port 48a and the first third converter line port 48e. The first first converter load port 50a and the second first converter load port 50b are connected to the first primary winding 56 of transformer 16c. The first second converter load port 50c and the second second converter load port 50d are connected to the second primary winding 64 of transformer 16c. The first third converter load port 50e and the second third converter load port 50f are connected to the third primary winding 68 of transformer 16c.

[0061] In one exemplary embodiment, a second exemplary embodiment of the primary side 16a includes one or more switch pairs forming a plurality of AC-to-AC converters for single-phase or three-phase AC line input. In a non-limiting example, the one or more switch pairs include unidirectional semiconductor switches. In another non-limiting example, the one or more switch pairs include bidirectional semiconductor switches forming one or more bidirectional switch pairs. In a second exemplary embodiment of the primary side 16a, the one or more bidirectional switch pairs include a first bidirectional switch pair, a second bidirectional switch pair, a third bidirectional switch pair, a fourth bidirectional switch pair, a fifth bidirectional switch pair, and a sixth bidirectional switch pair. In a second exemplary embodiment of the primary side 16a, a first bidirectional switch 52a is connected between a first terminal 54a of a first primary winding 56 of one or more primary windings of transformer 16c and a common node 58a of the first switch pair, while a second bidirectional switch 52b is connected between a second terminal 54b of the first primary winding 56 and the common node 58a of the first switch pair, as shown below. Figure 3 As shown.

[0062] In a second exemplary embodiment of the primary side 16a, a third bidirectional switch 52c is connected between the first terminal 54a and the common node 58b of the second switch pair, and a fourth bidirectional switch 52d is connected between the second terminal 54b and the common node 58b of the second switch pair, as follows: Figure 3As shown. In a second exemplary embodiment on the primary side 16a, a fifth bidirectional switch 52e is connected between the first terminal 62a of the second primary winding 64 of one or more primary windings of the transformer 16c and the common node 58c of the third switch pair, and a sixth bidirectional switch 52f is connected between the second terminal 62b of the second primary winding 64 and the common node 58c of the third switch pair, as shown. Figure 3 As shown. In the second exemplary embodiment of the primary side 16a, the seventh bidirectional switch 52g is connected between the first terminal 62a and the common node 58d of the fourth switch pair, and the eighth bidirectional switch 52h is connected between the second terminal 62b and the common node 58d of the fourth switch pair, as shown. Figure 3 As shown.

[0063] In a second exemplary embodiment on the primary side 16a, the fifth bidirectional switch pair includes a ninth bidirectional switch 52i connected between the first terminal 66a of the third primary winding 68 of one or more primary windings of the transformer 16c and the common node 58e of the fifth switch pair, and a tenth bidirectional switch 52j connected between the second terminal 66b of the third primary winding 68 and the common node 58e of the fifth switch pair (e.g., ...). Figure 3 (As shown). In a second exemplary embodiment of the primary side 16a, the sixth bidirectional switch pair includes an eleventh bidirectional switch 52k connected between the first terminal 66a and the common node 58f of the sixth switch pair, and a twelfth bidirectional switch 52l connected between the second terminal 66b and the common node 58f of the sixth switch pair, as shown. Figure 3 As shown.

[0064] In a second exemplary embodiment of the primary side 16a, the first switch pair common node 58a is electrically communicated with the first AC connection 32a via the first electrically controlled switch 34a, such as... Figure 3 As shown. The third switch communicates with the second AC phase 32b via the second electrical control switch 34b to the common node 58c, as shown. Figure 3 As shown. The fifth switch connects to the common node 58e via the third electrical control switch 34c and the third AC phase 32c for electrical communication, as shown. Figure 3 As shown. The second switch to common node 58b, the fourth switch to common node 58d, and the sixth switch to common node 58f communicate electrically with the neutral AC connection 32d through the sixth electrically controlled switch 34f, as shown. Figure 3 As shown. The fourth electrical control switch 34d is connected between the common node 58a of the first switch pair and the common node 58c of the third switch pair, as shown. Figure 3 As shown. The fifth electrical control switch 34e is connected between the common node 58a of the first switch pair and the common node 58e of the fifth switch pair, as follows. Figure 3 As shown. In an exemplary embodiment, if only single-phase operation is required, one or more of the multiple electronically controlled switches can be omitted.

[0065] In one exemplary embodiment, controller 14 is programmed to control the operation of the bidirectional switch pair using control terminals (e.g., gate terminals) to provide AC-to-AC power conversion from line connection port 30 to the first primary winding 56, the second primary winding 64, and the third primary winding 68, or from the first primary winding 56, the second primary winding 64, and the third primary winding 68 to line connection port 30. In a non-limiting example, controller 14 uses interleaved control methods, dual active bridge (DAB) control methods, capacitor-inductor-inductor-capacitor (CLLC) control methods, zero-voltage switching (ZVS) control methods, and / or similar methods to control the operation of the bidirectional switch pair. In a non-limiting example, controller 14 controls the operation of the bidirectional switch pair to provide additional functionality, such as power factor control (PFC).

[0066] In one exemplary embodiment, the controller 14 is programmed to control the operation of a plurality of electrically controlled switches to configure the primary side 16a for single-phase or three-phase operation (i.e., single-phase or three-phase line connection). Table 2 illustrates an exemplary control method for the plurality of electrically controlled switches in a second exemplary embodiment of the primary side 16a:

[0067]

[0068] Table 2

[0069] Wherein: S1 is the first electric control switch 34a, S2 is the second electric control switch 34b, S3 is the third electric control switch 34c, S4 is the fourth electric control switch 34d, S5 is the fifth electric control switch 34e, and S6 is the sixth electric control switch 34f. "Closed" means that the switch conducts current, and "open" means that the switch blocks current.

[0070] refer to Figure 4 A schematic diagram of a third exemplary embodiment of the primary side 16a is shown. Generally, the third exemplary embodiment of the primary side 16a includes a first primary AC-to-AC converter 42b, a second primary AC-to-AC converter 42c, and a third primary AC-to-AC converter 42d. The first primary AC-to-AC converter 42b has two first converter line ports and two first converter load ports, connected as described above, with reference to... Figure 3 The second primary AC-to-AC converter 42c has two second converter line ports and two second converter load ports, connected as described above, refer to [reference]. Figure 3 The third primary AC-to-AC converter 42d has two third converter line ports and two third converter load ports, connected as described above, refer to [reference]. Figure 3 .

[0071] In one exemplary embodiment, a third exemplary embodiment of the primary side 16a includes one or more switch pairs forming a plurality of AC-to-AC converters for single-phase or three-phase AC line inputs. In a non-limiting example, the one or more switch pairs include unidirectional semiconductor switches. In another non-limiting example, the one or more switch pairs include bidirectional semiconductor switches forming one or more bidirectional switch pairs. In the third exemplary embodiment of the primary side 16a, the one or more bidirectional switch pairs include a first bidirectional switch pair, a second bidirectional switch pair, and a third bidirectional switch pair.

[0072] In a third exemplary embodiment on the primary side 16a, a first bidirectional switch 52a is connected between the first AC phase connection 32a (via the first electrically controlled switch 34a) and the first switch pair common node 58a, and a second bidirectional switch 52b is connected between the neutral AC connection 32d (via the sixth electrically controlled switch 34f) and the first switch pair common node 58a, as shown below. Figure 4 As shown. The first terminal 54a of the first primary winding 56 is connected to the first bidirectional switch 52a via the first capacitor 72a and to the second bidirectional switch 52b via the second capacitor 72b, as follows. Figure 4 As shown. The second terminal 54b of the first primary winding 56 is connected to the common node 58a of the first switch pair, as shown. Figure 4 As shown.

[0073] In a third exemplary embodiment on the primary side 16a, a third bidirectional switch 52c is connected between the second AC phase connection 32b (via the second electrically controlled switch 34b) and the common node 58b of the second switch pair. A fourth bidirectional switch 52d is connected between the neutral AC connection 32d (via the sixth electrically controlled switch 34f) and the common node 58b of the second switch pair, as shown below. Figure 4 As shown. The first terminal 62a of the second primary winding 64 is connected to the third bidirectional switch 52c via the third capacitor 72c and to the fourth bidirectional switch 52d via the fourth capacitor 72d, as shown. Figure 4 As shown. The second terminal 62b of the second primary winding 64 is connected to the common node 58b of the second switch pair, as shown. Figure 4 As shown.

[0074] In the third exemplary embodiment of the primary side 16a, the fifth bidirectional switch 52e is connected between the third AC phase connection 32c (via the third electrically controlled switch 34c) and the third switch pair common node 58c. The sixth bidirectional switch 52f is connected between the neutral AC connection 32d (via the sixth electrically controlled switch 34f) and the third switch pair common node 58c, as shown below. Figure 4 As shown. The first terminal 66a of the third primary winding 68 is connected to the fifth bidirectional switch 52e via the fifth capacitor 72e and to the sixth bidirectional switch 52f via the sixth capacitor 72f, as... Figure 4 As shown. The second terminal 66b of the third primary winding 68 is connected to the common node 58c of the third switch pair, as shown. Figure 4 As shown.

[0075] In the third exemplary embodiment of the primary side 16a, the first bidirectional switch 52a is electrically connected to the third bidirectional switch 52c via the fourth electrically controlled switch 34d, as shown below. Figure 4 As shown. The first bidirectional switch 52a communicates electrically with the fifth bidirectional switch 52e via the fifth electronically controlled switch 34e, as follows. Figure 4 As shown. In an exemplary embodiment, if only single-phase operation is required, one or more of the multiple electronically controlled switches can be omitted.

[0076] In one exemplary embodiment, controller 14 is programmed to control the operation of the bidirectional switch pair using control terminals (e.g., gate terminals) to provide AC-to-AC power conversion from line connection port 30 to the first primary winding 56, the second primary winding 64, and the third primary winding 68, or from the first primary winding 56, the second primary winding 64, and the third primary winding 68 to line connection port 30. In a non-limiting example, controller 14 uses interleaved control methods, dual active bridge (DAB) control methods, capacitor-inductor-inductor-capacitor (CLLC) control methods, zero-voltage switching (ZVS) control methods, and / or similar methods to control the operation of the bidirectional switch pair. In a non-limiting example, controller 14 controls the operation of the bidirectional switch pair to provide additional functionality, such as power factor control (PFC).

[0077] In one exemplary embodiment, the controller 14 is programmed to control the operation of a plurality of electrically controlled switches to configure the primary side 16a for single-phase or three-phase operation (i.e., single-phase or three-phase line connection). Table 3 illustrates an exemplary control method for the plurality of electrically controlled switches in a third exemplary embodiment of the primary side 16a:

[0078]

[0079] Table 3

[0080] Wherein: S1 is the first electric control switch 34a, S2 is the second electric control switch 34b, S3 is the third electric control switch 34c, S4 is the fourth electric control switch 34d, S5 is the fifth electric control switch 34e, and S6 is the sixth electric control switch 34f. "Closed" means that the switch conducts current, and "open" means that the switch blocks current.

[0081] It should be understood that the first, second, and third exemplary embodiments of the primary side 16a are merely exemplary in nature without departing from the scope of this disclosure, and the primary side 16a may include other elements such as input filters (e.g., input filters with integrated inductors), output filters, passive components, feedback / control circuitry, and / or the like.

[0082] refer to Figure 5A and 5B The diagram shows an exemplary embodiment of the secondary side 16b. Figure 5B yes Figure 5A The following diagram continues. In one exemplary embodiment, the secondary side 16b includes at least one or more load connection ports 36 and one or more AC-to-DC converters. In some embodiments, the secondary side 16b also includes one or more AC-to-AC converters.

[0083] One or more load connection ports 36 are used to connect the secondary side 16b to one or more load devices, such as battery 40. Figure 1 One or more load connection ports 36 include at least one or more DC load connections, such as a first DC load connection 36a electrically connected to the battery 40 of vehicle 12. The one or more DC load connections allow the power converter 10 to supply power to / receive power from one or more DC loads, including, for example, the battery 40 of vehicle 12, one or more DC power systems, and / or the like. In a non-limiting example, the one or more load connection ports 36 may also include a second DC load connection 36b, a third DC load connection 36c, and / or any number of other DC load connections. In a non-limiting example, at least one of the one or more load connection ports is configured to provide a high-voltage DC output (e.g., 800 volts), at least one of the one or more load connection ports is configured to provide a low-voltage DC output (e.g., 12 volts), and at least one of the one or more load connection ports is configured to provide an AC output.

[0084] In one exemplary embodiment, DC load connections (e.g., second DC load connection 36b and third DC load connection 36c) are used to provide auxiliary power to other vehicle systems and / or other vehicle batteries. For example, first DC load connection 36a can provide a higher voltage level (e.g., 400 volts) to charge battery 40, while second DC load connection 36b and third DC load connection 36c can provide lower voltage levels (e.g., 48 volts, 12 volts and / or the like) to power other vehicle systems (e.g., ventilation systems, lighting systems, safety systems and / or similar systems).

[0085] One or more AC-to-DC converters are used to convert power to provide power to or receive power from one or more DC load connections. In an exemplary embodiment, the one or more AC-to-DC converters include one or more rectifiers. Each of the one or more rectifiers has an AC side connected to one or more secondary windings of transformer 16c and a DC side connected to one or more DC load connections of one or more load connection ports 36. In a non-limiting example, the first rectifier 80a has a first AC side 82a connected to the first primary winding 84a of transformer 16c and a first DC side 82b connected in parallel with a capacitor to the first DC load connection 36a, as shown below. Figure 5A As shown. The second rectifier 80b has a second AC side 86a connected to the second stage winding 84b of the transformer 16c, and a second DC side 86b connected in parallel with the first DC side 82b to the first DC load connection 36a, as shown. Figure 5A As shown. It should be understood that, as Figure 5A As shown in the ellipse, one or more rectifiers may include any number of rectifiers connected in parallel with the first DC load connection 36a to provide additional power delivery capacity to / from the first DC load connection 36a.

[0086] In a non-limiting example, the third rectifier 80c has a third AC side 88a and a third DC side 88b. The third AC side 88a is connected to the third stage winding 84c of the transformer 16c, and the third DC side 88b is connected to the second DC load connection 36b through one or more filter components, as shown below. Figure 5A As shown. The fourth rectifier 80d has a fourth AC side 90a and a fourth DC side 90b, wherein the fourth AC side 90a is connected to the fourth secondary winding 84d of the transformer 16c, and the fourth DC side 90b is connected to the third DC load connection 36c through one or more filter components, as shown. Figure 5A As shown. It should be understood that, as Figure 5A As shown by the ellipse in the diagram, one or more rectifiers may include any number of rectifiers connected to any number of other DC load connections to provide auxiliary power delivery capability to / from any number of other DC load connections. It should also be understood that one or more rectifiers may include other input and / or output filters, including passive and / or active filters.

[0087] In one exemplary embodiment, one or more rectifiers are full-wave rectifiers, including semiconductor devices (e.g., diodes) for converting alternating current (AC) to direct current (DC). In another exemplary embodiment, one or more rectifiers are active full-wave rectifiers, including active controllable semiconductor switches (e.g., MOSFETs) for converting AC to DC and controlling the DC output voltage, such as... Figure 5AAs shown. In a non-limiting example, the actively controllable semiconductor switch is controlled by controller 14. It should be understood that... Figure 5A The one or more rectifiers shown are merely exemplary in nature, and additional and / or alternative types of rectifiers are also within the scope of this disclosure.

[0088] refer to Figure 5B In one exemplary embodiment, one or more load connection ports 36 further include one or more AC load connections, and the secondary side 16b further includes one or more AC to AC converters.

[0089] In one exemplary embodiment, one or more AC load connections include, for example, a first AC load connection 36d (e.g., 120V / 50 or 60Hz AC, etc.), a second AC load connection 36e (240V / 50 or 60Hz, etc.), and / or any number of other AC load connections (three-phase 240V / 50 or 60Hz AC). One or more AC load connections allow the power converter 10 to supply power to / receive power from one or more AC loads. In a non-limiting example, one or more AC load connections allow the power converter 10 to supply power to / receive power from, for example, household appliances, tools, electrical appliances, electronic devices, and / or the like. In a non-limiting example, one or more AC load connections (e.g., the second AC load connection 36e) are in electrical communication with a vehicle-to-load (V2L) electrical socket 78. It should be understood that the V2L electrical socket 78 can be any type of socket or connector, and without departing from the scope of this disclosure, one or more AC load connections can be configured to provide AC outputs with various voltage and / or phase configurations (e.g., single-phase, split-phase, two-phase, three-phase, etc.).

[0090] One or more AC-to-AC converters are used to convert power to provide power to or receive power from one or more AC load connections. In an exemplary embodiment, each of the one or more AC-to-AC converters has a first side connected to one or more secondary windings of transformer 16c and a second side connected to one or more AC load connections of one or more load connection ports 36. In a non-limiting example, a first AC-to-AC converter 92a has a first side 94a and a second side 94b, the first side 94a being connected to the fifth secondary winding 84e of transformer 16c, and the second side 94b being connected to the first AC load connection 36d via an electronically controlled switch (e.g., a relay). Figure 5BAs shown. In a non-limiting example, the second AC-to-AC converter 92b has a first side 96a and a second side 96b, the first side 96a being connected to the sixth secondary winding 84f of the transformer 16c, and the second side 96b being connected to the second AC load connection 36e via an electrically controlled switch (e.g., a relay), as shown. Figure 5B As shown.

[0091] In one exemplary embodiment, one or more of the one or more AC-to-AC converters include one or more switch pairs. In one non-limiting example, the one or more switch pairs include unidirectional semiconductor switches. In another non-limiting example, the one or more switch pairs include bidirectional semiconductor switches forming one or more bidirectional switch pairs. In one non-limiting example, the first AC-to-AC converter 92a includes a seventh bidirectional switch pair and an eighth bidirectional switch pair. In the first AC-to-AC converter 92a, a thirteenth bidirectional switch 52m is connected between a first terminal 98a of the second side 94b of the first AC-to-AC converter 92a and a common node 58g of the seventh switch pair, and a fourteenth bidirectional switch 52n is connected between a second terminal 98b of the second side 94b of the first AC-to-AC converter 92a and a common node 58g of the seventh switch pair, as shown. Figure 5B As shown.

[0092] The fifteenth bidirectional switch 52o is connected between the first terminal 98a of the second side 94b of the first AC-to-AC converter 92a and the common node 58h of the eighth switch pair; the sixteenth bidirectional switch 52p is connected between the second terminal 98b of the second side 94b of the first AC-to-AC converter 92a and the common node 58h of the eighth switch pair. Figure 5B As shown. The seventh switch provides electrical communication between the common node 58g and the first terminal 100a of the fifth secondary winding 84e. The eighth switch provides electrical communication between the common node 58h and the second terminal 100b of the fifth secondary winding 84e.

[0093] In the second AC-to-AC converter 92b, the seventeenth bidirectional switch 52q is connected between the first terminal 102a of the second side 96b of the second AC-to-AC converter 92b and the common node 58i of the ninth switch pair, and the eighteenth bidirectional switch 52r is connected between the second terminal 102b of the second side 96b of the second AC-to-AC converter 92b and the common node 58i of the ninth switch pair. Figure 5B As shown.

[0094] The ninth switch communicates electrically with the common node 58i and the first terminal 104a of the sixth secondary winding 84f. The second terminal 104b of the sixth secondary winding 84f communicates electrically with the first terminal 102a of the second side 96b of the second AC-to-AC converter 92b via the seventh capacitor 72g, and with the second terminal 102b of the second side 96b of the second AC-to-AC converter 92b via the eighth capacitor 72h, as shown. Figure 5B As shown.

[0095] It should be understood that Figure 5B The one or more AC-to-AC converters shown (i.e., the first AC-to-AC converter 92a and the second AC-to-AC converter 92b) are merely exemplary in nature, and additional and / or alternative types of AC-to-AC converters are also within the scope of this disclosure. It should also be understood that, as Figure 5B As shown by the ellipse, one or more AC-to-AC converters may include any number of AC-to-AC converters connected to any number of AC load connections to provide AC power delivery capability to / from any number of additional AC load connections. For example, multiple AC-to-AC converters may be used in series to provide two-phase or three-phase AC output. It should also be understood that one or more AC-to-AC converters may include additional input and / or output filters, including passive and / or active filters.

[0096] It should be understood that Figure 5A and 5B The description of the secondary side 16b is merely exemplary, and without departing from the scope of this disclosure, the secondary side 16b may include any number and / or type of AC-to-DC and / or AC-to-DC converters. Furthermore, it should be understood that in one exemplary embodiment, any one or more of the various exemplary embodiments of the primary side 16a described above are electromagnetically coupled to the exemplary embodiment of the secondary side 16b described above via transformer 16c, thereby allowing bidirectional power transfer between the primary side 16a and the secondary side 16b.

[0097] refer to Figure 6 A schematic diagram of an exemplary embodiment of the power converter 10 is shown. In one exemplary embodiment, the primary side 16a includes one or more primary AC-to-AC converters 200, including, for example, a first primary AC-to-AC converter 200a and a second primary AC-to-AC converter 200b. It should be understood that the one or more primary AC-to-AC converters 200 may include any number of primary AC-to-AC converters 200, including only one primary AC-to-AC converter 200. It should be understood that the one or more primary AC-to-AC converters 200 can be configured according to reference... Figure 2 , 3Implemented by one or more exemplary embodiments discussed in 4, and / or implemented using additional or different circuitry, including, for example, single-stage converters, multi-stage converters and / or the like.

[0098] In one exemplary embodiment, the secondary side 16b includes one or more secondary AC-to-DC converters 300 and / or one or more secondary AC-to-AC converters 400. In a non-limiting example, the secondary side 16b includes: a first secondary AC-to-DC converter 300a configured to supply energy to / from the battery 40; a second secondary AC-to-DC converter 300b configured to supply energy to / from a 12-volt DC load / power source; and a third secondary AC-to-DC converter 300c configured to supply energy to / from a 48-volt DC load / power source. It should be understood that the one or more secondary AC-to-DC converters 300 may include any number of secondary AC-to-DC converters 300, including only one secondary AC-to-DC converter 300. Furthermore, the voltages discussed above are merely exemplary in nature, and additional / different voltages may be provided.

[0099] In a non-limiting example, the secondary side 16b also includes a first-stage AC-to-AC converter 400a configured to supply / receive energy to / from an AC load / power source (e.g., V2L socket 78 and / or other V2L applications), and a second-stage AC-to-AC converter 400b configured to supply / receive energy to / from an AC load / power source (e.g., V2L socket 78 and / or other V2L applications). It should be understood that one or more secondary AC-to-AC converters 400 may include any number of secondary AC-to-AC converters 400, including only one secondary AC-to-AC converter 400. Furthermore, one or more secondary AC-to-AC converters 400 may be configured to provide any voltage or phase output, including single-phase, split-phase, three-phase, and / or the like. It should be understood that one or more secondary AC-to-DC converters 300 and / or one or more secondary AC-to-AC converters 400 may use references... Figure 5A And / or one or more circuits discussed in 5B and / or implemented using additional or different circuits, such as single-stage converters, multi-stage converters and / or the like.

[0100] In a non-limiting example, transformer 16c is implemented as a multi-winding transformer having multiple primary windings and multiple secondary windings coupled through a common core. It should be understood that transformer 16c can be implemented with any winding and core configuration, as discussed in more detail above.

[0101] The power converter 10 disclosed herein offers several advantages. Using the power converter 10 in vehicle charging applications reduces the number of parts, weight, and size of the OBCM. Furthermore, the power converter 10 can simultaneously provide AC input (e.g., via line connection port 30) and AC output (e.g., via vehicle-to-load (V2L) electrical outlet 78). Additionally, the power converter 10 can operate at high frequencies, thereby reducing the size of capacitors and inductors. Moreover, the power converter 10 provides power factor control (PFC) functionality and can include an input filter with an integrated inductor, thereby reducing package size and harmonic noise.

[0102] The descriptions in this disclosure are merely exemplary in nature, and any modifications that do not depart from the spirit and scope of this disclosure are intended to fall within its scope. Such modifications should not be considered as departing from the spirit and scope of this disclosure.

Claims

1. A power converter, comprising: The primary side has a line connection port and multiple semiconductor switches; The secondary side has one or more AC-to-DC converters and one or more load connection ports; as well as One or more transformers configured to deliver power between the primary side and the secondary side.

2. The power converter according to claim 1, wherein the line connection port further comprises: Two or more of the following: The first AC connection; The second AC connection is available; The third exchange is connected; Neutral communication connection; as well as Multiple electrically controlled switches are connected to the first AC, the second AC, the third AC, and the neutral AC for electrical communication.

3. The power converter according to claim 2, wherein the plurality of semiconductor switches further comprises: One or more switch pairs, wherein the first switch of each of the one or more switch pairs is connected between a first terminal of a first primary winding of one or more primary windings of one or more transformers and a common node of the switch pair, wherein the second switch of each of the one or more switch pairs is connected between a second terminal of a first primary winding of one or more primary windings of one or more transformers and the common node of the switch pair, and wherein the common node of the switch pair is in electrical communication with the line connection port.

4. The power converter according to claim 3, wherein the one or more switch pairs further include: A first switch pair is connected between a first terminal of the first primary winding and a second terminal of the first primary winding, and has a first switch pair common node that is electrically connected to the first AC. The second switch pair is connected between the first terminal of the first primary winding and the second terminal of the first primary winding, and has a second switch pair common node that is electrically connected to the second AC. The third switch pair is connected between the first terminal of the first primary winding and the second terminal of the first primary winding, and has a common node of the third switch pair that is electrically connected to the third AC. as well as A fourth switch pair is connected between the first terminal of the first primary winding and the second terminal of the first primary winding, and has a common node of the fourth switch pair that is in electrical communication with the neutral AC connection.

5. The power converter according to claim 4, wherein the plurality of electronically controlled switches further comprises: A first electrically controlled switch is connected between the first AC phase connection and the first switch pair common node; A second electrically controlled switch is connected between the second AC phase connection and the common node of the second switch pair; A third electrically controlled switch is connected between the third AC phase connection and the common node of the third switch pair; A fourth electrically controlled switch is connected between the neutral AC connection and the common node of the fourth switch pair; The fifth electronically controlled switch is connected between the common node of the first switch pair and the common node of the second switch pair; as well as A sixth electrical control switch is connected between the common node of the third switch pair and the common node of the fourth switch pair.

6. The power converter according to claim 3, wherein the one or more switch pairs further include: A first switch pair is connected between a first terminal of the first primary winding and a second terminal of the first primary winding, and has a first switch pair common node that is electrically connected to the first AC. The second switch pair is connected between the first terminal of the first primary winding and the second terminal of the first primary winding, and has a second switch pair common node that is in electrical communication with the neutral AC connection. A third switch pair is connected between a first terminal of a second primary winding and a second terminal of a second primary winding of one or more primary windings of the one or more transformers, and has a common node of the third switch pair that is electrically connected to the second AC. A fourth switch pair is connected between the first terminal of the second primary winding and the second terminal of the second primary winding, and has a common node of the fourth switch pair that is in electrical communication with the neutral AC connection. A fifth switch pair is connected between the first terminal of the third primary winding of one or more primary windings of the one or more transformers and the second terminal of the third primary winding, and has a common node of the fifth switch pair that is electrically connected to the third AC. as well as A sixth switch pair is connected between the first terminal of the third primary winding and the second terminal of the third primary winding, and has a common node of the sixth switch pair that is in electrical communication with the neutral AC connection.

7. The power converter according to claim 6, wherein the plurality of electronically controlled switches further comprises: A first electrically controlled switch is connected between the first AC phase connection and the first switch pair common node; A second electrically controlled switch is connected between the second AC phase connection and the common node of the third switch pair; A third electrical control switch is connected between the third AC phase connection and the common node of the fifth switch pair; A fourth electronically controlled switch is connected between the common node of the first switch pair and the common node of the third switch pair; The fifth electronically controlled switch is connected between the common node of the first switch pair and the common node of the fifth switch pair; as well as A sixth electrical control switch is connected between the neutral AC connection and the second switch pair common node, the fourth switch pair common node, and the sixth switch pair common node.

8. The power converter of claim 1, wherein the one or more AC-to-DC converters further comprises: One or more active full-wave rectifiers, wherein the AC side of each of the one or more active full-wave rectifiers is connected to one or more secondary windings of the one or more transformers, and wherein the DC side of each of the one or more active full-wave rectifiers is connected in parallel to one or more DC loads connected to the one or more load connection ports.

9. The power converter according to claim 1, wherein the secondary side further comprises: One or more AC-to-AC converters, wherein a first side of each of the one or more AC-to-AC converters is connected to one or more secondary windings of the one or more transformers, and wherein a second side of each of the one or more AC-to-AC converters is connected to one or more AC load connections of the one or more load connection ports.

10. The power converter of claim 9, wherein the one or more AC-to-AC converters further comprises: One or more switch pairs, wherein a first switch of each of the one or more switch pairs is connected between a first terminal of the one or more AC load connection and a common node of the switch pair, wherein a second switch of each of the one or more switch pairs is connected between a second terminal of the one or more AC load connection and the common node of the switch pair, and wherein the common node of the switch pair is in electrical communication with one or more secondary windings of the one or more transformers.

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