Systems and methods for configurable primary and secondary DC-DC converter and battery charger
A system for a direct current (DC) to DC converter, the system comprising one or more transformers, a first bridge driver connected to a primary side of the one or more transformers, a second bridge driver connected to a primary side of the one or more transformers, one or more primary configuration switches operable to configure the first bridge driver and the second bridge driver into each of a single driver configuration, a parallel driver configuration, and a series driver configuration, a first bridge rectifier connected to a secondary side of the one or more transformers, a second bridge rectifier connected to the secondary side of the one or more transformers, and one or more secondary configuration switches operable to configure the first bridge rectifier and the second bridge rectifier into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration.
1 . A system for a direct current (DC) to DC converter, the system comprising:
one or more transformers;
a first bridge driver connected to a primary side of the one or more transformers;
a second bridge driver connected to a primary side of the one or more transformers;
one or more primary configuration switches operable to configure the first bridge driver and the second bridge driver into each of a single driver configuration, a parallel driver configuration, and a series driver configuration;
a first bridge rectifier connected to a secondary side of the one or more transformers;
a second bridge rectifier connected to the secondary side of the one or more transformers; and
one or more secondary configuration switches operable to configure the first bridge rectifier and the second bridge rectifier into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration.
2 . The system of claim 1 , further comprising:
a controller configured to control the operation of the one or more primary configuration switches and the one or more secondary configuration switches.
3 . The system of claim 2 , wherein the one or more primary configuration switches include a first primary configuration switch, a second primary configuration switch, and a third primary configuration switch, and
the one or more secondary configuration switches include a first secondary configuration switch, a second secondary configuration switch, and a third secondary configuration switch.
4 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more primary configuration switches to configure the first bridge driver and the second bridge driver in the single driver configuration by controlling the first primary configuration switch to be open, the second primary configuration switch to be open, and the third primary configuration switch to be closed.
5 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more primary configuration switches to configure the first bridge driver and the second bridge driver in the parallel driver configuration by controlling the first primary configuration switch to be closed, the second primary configuration switch to be open, and the third primary configuration switch to be closed.
6 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more primary configuration switches to configure the first bridge driver and the second bridge driver in the series driver configuration by controlling the first primary configuration switch to be open, the second primary configuration switch to be closed, and the third primary configuration switch to be open.
7 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more secondary configuration switches to configure the first bridge rectifier and the second bridge rectifier in the single rectifier configuration by controlling the first secondary configuration switch to be open, the second secondary configuration switch to be open, and the third secondary configuration switch to be closed.
8 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more secondary configuration switches to configure the first bridge rectifier and the second bridge rectifier in the parallel rectifier configuration by controlling the first secondary configuration switch to be closed, the second secondary configuration switch to be open, and the third secondary configuration switch to be closed.
9 . The system of claim 3 , wherein the controller is configured to control the operation of the one or more secondary configuration switches to configure the first bridge rectifier and the second bridge rectifier in the series rectifier configuration by controlling the first secondary configuration switch to be open, the second secondary configuration switch to be closed, and the third secondary configuration switch to be open.
10 . The system of claim 2 , further comprising:
wherein the controller is further configured to control the operation of the one or more primary configuration switches and the one or more secondary configuration switches to configure the first bridge driver, second bridge driver, first bridge rectifier, and second bridge rectifier based on a sensed voltage of a battery connected to the DC-DC converter being in a low voltage region, a nominal voltage region, or a full voltage region.
11 . The system of claim 2 , wherein the controller is further configured to control the operation of one or more of the first bridge driver and second bridge driver to operate in each of a half-bridge driver configuration and in a full-bridge driver configuration.
12 . The system of claim 2 , wherein the controller is further configured to turn off switches of the second bridge driver in the single driver configuration, and to turn off switches of the second bridge rectifier in the single rectifier configuration.
13 . The system of claim 1 , further comprising:
an alternating current (AC) to direct current (DC) Power Factor Correction (PFC) converter connected to the bridge driver to provide the system as a battery charger, and
a battery connected to the DC-DC converter of the battery charger,
wherein the battery charger is configured to:
receive input AC power through the PFC converter, convert the AC power to DC power, and provide the DC power to the battery to charge the battery, and
receive DC power from the battery through the DC-DC converter, convert the DC power to AC power, and provide the AC power through the PFC converter as output AC power.
14 . The system of claim 1 , wherein the one or more transformers includes one or more high-frequency transformers provided in a resonant tank including one or more of a multiple winding transformer or multiple transformers.
15 . A method for controlling a system including a direct current (DC) to DC converter including one or more transformers, a first bridge driver, a second bridge driver, one or more primary configuration switches, a first bridge rectifier, a second bridge rectifier, and one or more secondary configuration switches, the method comprising performing, by a controller, operations including:
controlling a switching operation of the one or more primary configuration switches to configure the first bridge driver and the second bridge driver into each of a single driver configuration, a parallel driver configuration, and a series driver configuration; and
controlling a switching operation of the one or more secondary configuration switches to configure the first bridge rectifier and the second bridge rectifier into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration.
16 . The method of claim 15 , wherein the operations further include receiving a sensed voltage of a battery connected to the DC-DC converter, and
wherein the controlling the switching operation includes controlling the switching operation to configure the first bridge driver, second bridge driver, first bridge rectifier, and second bridge rectifier based on the sensed voltage of the battery connected to the DC-DC converter being in a low voltage region, a nominal voltage region, or a full voltage region.
17 . The method of claim 15 , wherein the operations further include controlling the operation of one or more of the first bridge driver and second bridge driver to operate in each of a half-bridge driver configuration and in a full-bridge driver configuration.
18 . The method of claim 15 , wherein the controlling the switching operation of the one or more primary configuration switches to configure the first bridge driver and the second bridge driver in the single driver configuration includes turning off switches of the second bridge driver, and
wherein the controlling the switching operation of the one or more secondary configuration switches to configure the first bridge rectifier and the second bridge rectifier in the single rectifier configuration includes turning off switches of the second bridge rectifier.
19 . The method of claim 15 , wherein the controlling the switching operation further includes:
receiving input AC power, converting the AC power to DC power, and providing the DC power to a battery to charge the battery, and
receiving DC power from the battery, converting the DC power to AC power, and providing the AC power as output AC power.
20 . A non-transitory computer readable medium storing instructions that, when executed by one or more processors, perform operations including:
controlling a switching operation of one or more primary configuration switches to configure a first bridge driver and a second bridge driver into each of a single driver configuration, a parallel driver configuration, and a series driver configuration; and
controlling a switching operation of one or more secondary configuration switches to configure a first bridge rectifier and a second bridge rectifier into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration.