Hella Gmbh & Co Kgaa

Hella Kgaa Hueck and Company

Kettering University

Fca US LLC

Hella Corporate Center Usa, Inc.

Conductive Holding, LLC

Hua Bai

Juncheng Lu

Xuntuo Wang

Hui Teng

Alexander Balogh

Alan Wayne Brown

Bing Cheng

Young Joo Lee

Mengyang Zhang

Fei Yang

Allan Taylor

Zhong Nie

Dennis Krozek

Fred A Householder

Wei Guo

Chen Duan

Xuan Zhou

Ahmad Arshan Khan

An apparatus includes a controller, a switching block, and a three-phase bidirectional AC/DC converter. The switching block has a first interface connected to a power grid, a second interface connected to an electric motor, and a third interface connected to the three-phase bidirectional AC/DC converter that includes first, second, and third single-phase AC/DC conversion modules, and which have inputs and outputs joined at an output node, and a respective transformer configured to provide electrical isolation. In a first mode of operation, the switching block connects the power grid to the AC/DC converter for charging a battery connected to the output node and disconnects the electric motor. In a second mode of operation, the switching block disconnects the power grid and connects the electric motor to the AC/DC converter which is controlled to convert DC power drawn from the battery to energize the electric motor.

Apparatus to realize fast battery charging and motor driving for electric vehicles using one AC/DC converter

In one embodiment, a bidirectional DC/DC converter includes a DC/AC inverter having active switches (e.g., MOSFETs), and an AC/DC rectifier having a capacitor that performs DC-bias current blocking and active switches (e.g., MOSFETs) arranged in a bridge configuration. A microcontroller is coupled to the active switches of the DC/AC inverter and AC/DC rectifier and configured to provide control signals thereto according to a control algorithm that, when power is to flow in a forward direction, sends control signals to operate the active switches of the DC/AC inverter at a duty cycle and to disable the active switches of the AC/DC rectifier, and when power is to flow in a reverse direction, sends control signals to operate the active switches of the DC/AC inverter to disable the active switches of the DC/AC inverter and operates the active switches of the AC/DC rectifier at a duty cycle.

Bidirectional DC/DC converter for a charging system

An AC/DC conversion apparatus includes first, second, and third AC/DC conversion modules operated by a controller in two modes of operation. In the first mode, the input AC signal is 3-phase and each of the three modules are enabled to handle a respective one of the input phases. In the second mode, the input AC signal is single phase and the first and second modules are enabled to deliver output power based on the single-phase AC input, while the controller actuates an H-bridge switches in the third module to which active filter circuitry is connected, to reduce an AC component in the output signal. The active filter circuitry can be selectively connected to the H-bridge switches when single-phase operation is desired, which circuitry may be disposed in a filter housing having male electrical terminals that cooperate with corresponding female terminals associated with the third module.

Electric power conversion apparatus having single-phase and multi-phase operation modes

A hybrid switch apparatus includes a gate drive circuit producing a gate drive signal, a GaN high electron mobility transistor (HEMT) having a first gate, a first drain, and a first source. A silicon (Si) MOSFET has a second gate, a second drain, and a second source. The GaN HEMT and the Si MOSFET are connected in a parallel arrangement so that (i) the first drain and the second drain are electrically connected and (ii) the first source and the second source are electrically connected. The second gate is connected to the gate drive circuit output to receive the gate drive signal. A delay block has an input connected to the gate drive circuit output and an delay block output is configured to produce a delayed gate drive signal for driving the GaN HEMT.

Hybrid switch including GaN HEMT and MOSFET

A power transfer system and method are provided for transferring power from an AC supply outputting a first AC voltage. The system includes a controller and a matrix converter coupled to the AC supply for converting the first AC voltage to a second AC voltage. A primary coil is connected to the matrix converter and a secondary coil is in communication with the primary coil for producing an induced AC voltage. A secondary rectifier is connected to the secondary coil for rectifying the induced AC voltage to produce a secondary DC voltage. A sensor is coupled to the secondary rectifier and to the controller for monitoring the secondary DC voltage and outputting a proportional signal. The controller is configured to control the matrix converter producing a desired second AC voltage at a desired operating frequency and maintain a predetermined secondary DC voltage in response to the signal from the sensor.

Power transfer system

A single-phase AC/DC electric power conversion apparatus includes an indirect matrix converter having an input interface to receive a first alternating current (AC) signal and an output interface to produce a second AC signal, where the first AC signal has a grid frequency. A transformer has a primary winding and an electrically isolated and magnetically coupled secondary winding. A coupling inductor is connected in series between the output interface of the indirect matrix converter and the primary winding. An H-bridge switching arrangement is connected to the secondary winding and produces an output signal having a DC component and at least one AC component. The at least one AC component has a second order harmonic of the grid frequency. An active filter reduces the second order harmonic AC component. A modular conversion apparatus for three-phase power replicates the single-phase apparatus as a module for each phase and omits the active filter.

Electric power conversion apparatus with active filter

In one embodiment, a bidirectional battery charger integrated with renewable energy generation includes a primary side AC/DC rectifier coupled to the electrical grid and a first DC bus, a DC/AC inverter coupled to the first DC bus and a primary winding, a secondary side AC/DC rectifier coupled to a secondary winding and a battery, and a boost converter coupled to a renewable energy generator and the first DC bus. The boost converter includes an active switch controlled by a control algorithm that, when renewable power is available, operates the active switch at a duty cycle that allows power to flow from the renewable energy generator to the first DC bus and on to charge the battery (without passing though the primary side AC/DC rectifier) or on to supply the electrical grid (without passing through the DC/AC inverter and secondary side AC/DC rectifier), and, when not available, disables the active switch.

Bidirectional battery charger integrated with renewable energy generation

An apparatus includes a gate drive circuit and a GaN HEMT switch where the gate drive circuit has a gate drive output to produce a gate drive signal in response to a gate control signal. The switch has a gate connected to the gate drive circuit through a gate drive resistor. The gate drive circuit includes a NPN (or NMOS) turn-on transistor and a PNP (or PMOS) turn-off transistor. The gate drive circuit includes a turn-on resistor with a first resistance coupled to the turn-on transistor and a turn-off resistor with a second resistance coupled to the turn-off transistor. The turn-on and turn-off transistors, gate drive resistor, the switching device, but not the turn-on and turn-off resistors are disposed in an integrated circuit to reduce a gate-drive loop inductance. The first and second resistances can be different to adjust the turn-on and turn-off speeds of the switching device.

Gate drive circuit for power conversion apparatus

A driver circuit has a gate drive terminal that produces a gate drive signal to control paralleled power semiconductor switches, such as GaN high electron mobility transistor (HEMT) devices. One of the switches is closest to the gate drive terminal such that its gate drive loop inductance is smaller than the remaining switches that are farther away having a larger loop inductance. An additional resistor or gate-source capacitor is provided in the gate drive circuit of the closest switch which increases the total gate resistance of the closest switch compared to the remaining switches, which delays the turn off time of the closest switch. The delay permits zero voltage switching turn-off of the remaining switches to reduce noise. The closest switch is hard switched off but has the smallest loop inductance, which allows optimized turn off.

Gate drive circuit

Techniques are presented for synchronous rectification control (SRC) of a DC-DC converter in an electrified vehicle (EV) can include determining a required output current for the DC-DC converter based on a secondary voltage of a secondary battery system of the EV, the DC-DC converter being configured to convert a primary voltage from a primary battery system of the EV to the secondary voltage. The techniques can include determining, at the controller, a switching frequency for the DC-DC converter that causes the DC-DC converter to output the required output current. The techniques can include determining turn-on and turn-off delays of the DC-DC converter based on the required output current and the switching frequency using one or more look-up tables. The techniques can also include controlling the DC-DC converter efficiency based on the turn-on and turn-off delays.

Techniques for synchronous rectification control of DC-DC converters in electrified vehicles

A system and method for controlling an interior permanent magnet synchronous motor (IPMSM) are presented. In an exemplary implementation, phase current ripple estimation techniques are utilized for variable frequency switching pulse-width modulation control of the IPMSM. In one implementation, the method includes controlling a three-phase inverter based on an initial switching frequency to generate a three-phase alternating current (AC) voltage for the IPMSM. Transformed voltages are determined in a rotating reference frame based on the three-phase AC voltage in the stationary reference frame. Current ripples are determined in the rotating reference frame based on the transformed voltages. Phase current ripples are determined in the stationary reference frame based on the current ripples in the rotating reference frame. A modified switching frequency for the three-phase inverter is determined based on the initial switching frequency and the phase current ripples. The three-phase inverter is then controlled based on the modified switching frequency.

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