Systems and methods for stacked multi-level power converter implementations with linear scaling
View Patent ↗Disclosed are methods, systems, devices, and other implementations, including a voltage converter system that includes a plurality of energy storage elements, a plurality of switching devices, each of which is in electrical communication with at least one of the plurality of the storage elements, with the plurality of storage elements and the plurality of switching devices being configured in a multi-level arrangement of multiple voltage converting cells. The system further includes a plurality of controllers to actuate one or more of the plurality of switching devices to independently control voltage levels of at least one energy storage element of the multiple voltage converting cells. In some embodiments, the cells may include an arrangement of two capacitors and an inductor that define a buck-boost converter circuit. Alternatively, the cells may have a Dual Active Half Bridge (DAHB) converter configuration with a primary side separated from a secondary side by a transformer.
1 . A voltage converter system comprising:
a plurality of energy storage elements;
a plurality of switching devices, each in electrical communication with at least one of the plurality of the energy storage elements, wherein the plurality of energy storage elements and the plurality of switching devices are configured in a multi-level arrangement of multiple voltage converting cells; and
a plurality of controllers to controllably actuate one or more of the plurality of switching devices to independently control voltage levels of at least one energy storage element of the multiple voltage converting cells.
2 . The voltage converter system of claim 1 , wherein each of the multiple voltage converting cells comprises an arrangement of two capacitors and an inductor that define a buck-boost converter circuit.
3 . The voltage converter system of claim 1 , wherein the multiple voltage converting cells are arranged as one or more stacked cascades of converting cells, with each voltage converting cell in the one or more stacked cascades of conversion cells sharing at least one capacitor element with a neighboring voltage converting cell.
4 . The voltage converter system of claim 1 , wherein the plurality of controllers configured to independently control the voltage levels of the at least one energy storage element of each of the multiple voltage converting cells is configured to achieve a voltage balance for the multiple voltage converting cells.
5 . The voltage converter system of claim 1 , wherein the plurality of controllers, configured to independently control the voltage levels of the at least one energy storage element of the each of the multiple voltage converting cells, is configured to determine and maintain at least one capacitor of the multiple voltage converting cells at a respective voltage level.
6 . The voltage converter system of claim 1 , wherein the plurality of controllers configured to controllably actuate the one or more of the plurality of switching devices is configured to controllably actuate the one or more of the plurality of switching devices based at least in part on measured electrical properties of at least one of the multiple voltage converting cells.
7 . The voltage converter system of claim 6 , wherein the plurality of controllers is configured to actuate the one or more of the plurality of switching devices according to a voltage level measured across at least one of the plurality energy storage elements.
8 . The voltage converter system of claim 1 , wherein the plurality of controllers configured to controllably actuate the one or more of the plurality of switching devices includes at least one controller configured to determine an adjustable duty cycle behavior for at least one of the multiple voltage converting cells.
9 . The voltage converter system of claim 8 , wherein the at least one controller configured to determine the adjustable duty cycle behavior for the at least one of the multiple voltage converting cells is configured to continually compute the duty cycle behavior for the at least one of the multiple voltage converting cells that achieves a pre-determined output voltage for the voltage converter system, with other of the multiple voltage converting cells, excluding the at least one of the multiple voltage converting cells, configured with respective substantially fixed duty cycle values.
10 . The voltage converter system of claim 8 , wherein the plurality of controllers configured to determine the adjustable duty cycle behavior for the at least one of the multiple voltage converting cells is configured to derive duty cycle characteristics for the multiple voltage converting cells to achieve a desired output voltage for the voltage converter system that optimizes one or more objective functions.
11 . The voltage converter system of claim 10 , wherein the one or more objective functions includes one or more of: a) 1-norm objective function of all inductor currents in the voltage converter system to minimize overall current rating of the voltage converter system, b) a 2-norm squared objective function of all the inductor currents of the voltage converter system to minimize overall power loss in the voltage converter system, or c) an inf-norm objective function of all the inductor currents of the voltage converter system to minimize maximum currents levels in all the inductor currents.
12 . The voltage converter system of claim 1 , wherein at least one of the multiple voltage converting cells comprises a Dual Active Half Bridge (DAHB) converter configuration cell that includes a primary side and a secondary side separated from the primary side by a transformer, with the primary side including one or more primary side energy storage elements and one or more primary side switches, and with the secondary side including one or more secondary side energy storage elements and one or more secondary side switching devices.
13 . The voltage converter system of claim 12 , wherein the at least one DAHB converter configuration cell includes two primary side capacitors, two primary side controllable switching devices, two secondary side capacitors, and two secondary side switching devices.
14 . The voltage converter system of claim 13 , wherein the plurality of controllers configured to independently control the voltage levels of the at least one energy storage element of each of the multiple voltage converting cells includes at least one dedicated controller for the at least one DAHB converter configuration cell, the at least one dedicated controller configured to controllably actuate the two primary side switching devices and the two secondary side switching devices according to one or more pre-determined switching sequences defined for a particular time interval.
15 . The voltage converter system of claim 14 , wherein the one or more switching sequences for the at least one DAHB converter configuration cell is defined by duty cycles for the primary side and for the secondary side, and by a phase shift, φ, between a primary side and a secondary side switching events.
16 . The voltage converter system of claim 12 , wherein the multiple voltage converting cells each includes a respective cell with the DAHB converter configuration cell, and wherein the multiple voltage converting cells are arranged as one or more stacked cascades of the cells with the DAHB converter configuration cell connected to a load.
17 . The voltage converter system of claim 1 , wherein the multi-level arrangement of the multiple voltage converting cells comprises a plurality of voltage converting cells arranged in multiple stacks of voltage converting cells connected to a load, and wherein the plurality of controllers comprises a central controller in electrical communication with the multiple stacks of voltage converting cells to control electrical currents produced by the multiple stacks to power the load.
18 . The voltage converter system of claim 17 , wherein the load comprises a multi-phase motor, with each of the multiple stacks of voltage converter cells providing a respective phased current for one of multi-phase inputs of the multi-phase motors, and wherein the central controller is configured to control duty cycles of one or more switching devices in the multiple stacks to produce the multi-phase currents that result in one or more of a specified motor speed or a specified motor torque.
19 . The voltage converter of claim 17 , wherein the plurality of controllers comprises an individual cell controller for each of the multiple voltage converting cells, with the each of the multiple voltage converting cells comprising two capacitors, two switching devices, and an inductor element arranged in a buck-boost converter configuration, and wherein the each individual cell controller for the each of the multiple voltage converting cells is configured to maintain a ratio between a first and second voltage levels of non-common terminals of the two capacitors at a specified level.
20 . A voltage conversion method comprising:
obtaining electrical properties data representative of electrical properties of a voltage converter system comprising a plurality of energy storage elements and a plurality of switching devices, with each of the plurality of switching devices being electrically coupled to at least one of the plurality of the energy storage elements, wherein the plurality of energy storage elements and the plurality of switching devices are configured in a multi-level arrangement of multiple voltage converting cells; and
controllably actuating by a plurality of controllers coupled to the multiple voltage converting cells, based at least in part on the electrical properties data, one or more of the plurality of the switching devices to independently control voltage levels of at least one energy storage element of the multiple voltage converting cells.
21 . The method of claim 20 , wherein each of the multiple voltage converting cells comprises an arrangement of two capacitors and an inductor that define a buck-boost converter circuit.
22 . The method of claim 20 , wherein controllably actuating the one or more of the plurality of switching devices comprises independently controlling the voltage levels of the at least one energy storage element of each of the multiple voltage converting cells to achieve a voltage balance for the multiple voltage converting cells.
23 . The method of claim 20 , wherein controllably actuating the one or more of the plurality of switching devices comprises controllably actuating the one or more of the plurality of switching devices according to a voltage level measured across at least one of the plurality energy storage elements.
24 . The method of claim 20 , wherein controllably actuating the one or more of the plurality of switching devices comprises:
determining an adjustable duty cycle behavior for at least one of the multiple voltage converting cells.
25 . The method of claim 24 , wherein determining the adjustable duty cycle behavior for the at least one of the multiple voltage converting cells comprises continually computing the duty cycle behavior for the at least one of the multiple voltage converting cells that achieves a pre-determined output voltage for the voltage converter system, with other of the multiple voltage converting cells, excluding the at least one of the multiple voltage converting cells, configured with respective substantially fixed duty cycle values.
26 . The method of claim 24 , wherein determining the adjustable duty cycle behavior for the at least one of the multiple voltage converting cells comprises deriving duty cycle characteristics for the multiple voltage converting cells to achieve a desired output voltage for the voltage converter system that optimizes one or more objective functions.
27 . The method of claim 26 , wherein the one or more objective functions includes one or more of: a) 1-norm objective function of all inductor currents in the voltage converter system to minimize overall current rating of the voltage converter system, b) a 2-norm squared objective function of all the inductor currents of the voltage converter system to minimize overall power loss in the voltage converter system, or c) an inf-norm objective function of all the inductor currents of the voltage converter system to minimize maximum currents levels in all the inductor currents.
28 . The method of claim 20 , wherein at least one of the multiple voltage converting cells comprises a Dual Active Half Bridge (DAHB) converter configuration cell that includes a primary side and a secondary side separated from the primary side by a transformer, with the primary side including one or more primary side energy storage elements and one or more primary side switches, and with the secondary side including one or more secondary side energy storage elements and one or more secondary side switching devices.
29 . The method of claim 28 , wherein the at least one DAHB converter configuration cell includes two primary side capacitors, two primary side controllable switching devices, two secondary side capacitors, and two secondary side switching devices, and wherein controllably actuating the one or more of the plurality of switching devices comprises controllably actuating the two primary side switching devices and the two secondary side switching devices according to one or more pre-determined switching sequences defined for a particular time interval.
30 . The method of claim 29 , wherein the one or more switching sequences for the at least one DAHB converter configuration cell is defined by duty cycles for the primary side and for the secondary side, and by a phase shift, φ, between a primary side and a secondary side switching events.
31 . The method of claim 20 , wherein the multi-level arrangement of the multiple voltage converting cells comprises a plurality of voltage converting cells arranged in multiple stacks of voltage converting cells connected to a load, and wherein controllably actuating the one or more of the plurality of the switching devices comprises controlling, by a central controller from the plurality of controllers, electrical currents produced by the multiple stacks to power the load.
32 . The method of claim 31 , wherein the load comprises a multi-phase motor, with each of the multiple stacks of voltage converter cells providing a respective phased current for one of multi-phase inputs of the multi-phase motors, and wherein controlling, by the central controller, the electrical currents produced by the multiple stacks comprises controlling duty cycles of one or more switching devices in the multiple stacks to produce the multi-phase currents that result in one or more of a specified motor speed or a specified motor torque.
33 . The method of claim 31 , wherein controllably actuating the one or more of the plurality of switching devices further comprises controlling individually, by a dedicated cell controller for at least one of the multiple voltage converting cells, the at least one of the multiple voltage converting cells that includes two capacitors, two switching devices, and an inductor element arranged in a buck-boost converter configuration, to maintain a ratio between a first and second voltage levels of non-common terminals of the two capacitors at a specified level.
34 . The method of claim 20 , wherein the multi-level arrangement of the multiple voltage converting cells comprises a plurality of voltage converting cells arranged in multiple stacks of voltage converting cells connected to a load, with each of the multiple voltage converting cell including a dedicated cell controller, and wherein controllably actuating the one or more of the plurality of the switching devices comprises controllably actuating, by the respective dedicated cell controller for the each of the multiple voltage converting cells, the one or more of the plurality of the switching devices to independently control voltage levels of the at least one energy storage element of the multiple voltage converting cells.
35 . A non-transitory computer readable media storing a set of instructions, executable on at least one programmable device, to:
obtain electrical properties data representative of electrical properties of a voltage converter system comprising a plurality of energy storage elements and a plurality of switching devices, with each of the plurality of switching devices being in electrical communication with at least one of the plurality of the energy storage elements, wherein the plurality of energy storage elements and the plurality of switching devices are configured in a multi-level arrangement of multiple voltage converting cells; and
controllably actuate by a plurality of controllers coupled to the multiple voltage converting cells, based at least in part on the electrical properties data, one or more of the plurality of the switching devices to independently control voltage levels of at least one energy storage element of the multiple voltage converting cells.