Granted Patent B2

US 12,643,420 · App. 18/497,514 · Granted Jun 2, 2026

Inventors: Venkata Jaya Sai Praneeth Ammanamanchi (Lamadelaine, LU); Alexandre M. S. Reis (Westfield, IN); Joseph A. Engel (Oberkorn, LU); Scott E. Bauer (Holly, MI)

Assignee: BorgWarner US Technologies LLC

B60L53/22H02M1/4208H02M3/33584B60L2210/12B60L2210/14B60L2210/30

Abstract

Claims (50)

1 . A system comprising:

an alternating current (AC) to direct current (DC) converter (AC-DC converter), the AC-DC converter connectable to a line voltage;

a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including:

a high voltage buck-boost converter having a secondary side connectable to a high voltage battery, the high voltage buck-boost converter including a first high voltage switch and a second high voltage switch, wherein the high voltage buck-boost converter is configured to operate in one or more modes, including at least one mode of the one or more modes where the first high voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second high voltage switch;

a low voltage buck-boost converter having a secondary side connectable to a low voltage battery, the low voltage buck-boost converter including a first low voltage switch and a second low voltage switch, wherein the low voltage buck-boost converter is configured to operate in one or more modes, including at least one mode of the one or more modes where the first low voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second low voltage switch; and

one or more transformers having a primary side connected to the AC-DC converter, a secondary side connected to a primary side of the high voltage buck-boost converter, and a tertiary side connected to a primary side of the low voltage buck-boost converter; and

one or more controllers configured to control an operation of the high voltage buck-boost converter and the low voltage buck-boost converter to control a power transfer between two or more of the line voltage, the high voltage battery, or the low voltage battery;

wherein the one or more controllers control an operation of the first high voltage switch, the second high voltage switch, the first low voltage switch, and the second low voltage switch to configure the DC-DC converter into each of (i) a charging mode with both an HV and LV buck operation, (ii) a charging mode with an LV only buck operation, wherein the first high voltage switch is in the closed state and the second high voltage switch is in the open state, (iii) an HV to LV conversion mode with HV and LV buck operation, (iv) an HV to LV conversion mode with HV only buck operation, wherein the first low voltage switch is in the closed state and the second low voltage switch is in the open state, and (v) an HV to LV conversion mode with no HV or LV buck operation, wherein the first high voltage switch is in the closed state, the second high voltage switch is in the open state, the first low voltage switch is in the closed state, and the second low voltage switch is in the open state.

2 . The system of claim 1 , wherein the DC-DC converter further includes:

a high voltage bridge rectifier connected to the secondary side of the one or more transformers and the primary side of the high voltage buck-boost converter; and

a low voltage bridge rectifier connected to the tertiary side of the one or more transformers and the primary side of the low voltage buck-boost converter.

3 . The system of claim 1 , wherein the one or more controllers are further configured to operate the DC-DC converter in a capacitor pre-charge operation, wherein the first high voltage switch is in the closed state and the second high voltage switch is in the open state.

4 . The system of claim 1 , wherein the DC-DC converter further includes:

a middle voltage buck-boost converter having a primary side connected in parallel with the low voltage buck-boost converter and a secondary side connectable to a middle voltage battery.

5 . The system of claim 1 , wherein the DC-DC converter further includes:

a bridge driver having a primary side connected to the AC-DC converter and a secondary side connected to the one or more transformers.

6 . The system of claim 1 , wherein the DC-DC converter further includes:

one or more of a primary transformer isolation switch, a high voltage isolation switch, or a low voltage isolation switch.

7 . The system of claim 6 , wherein the one or more controllers are further configured to control an operation of the one or more of the primary transformer isolation switch, the high voltage isolation switch, or the low voltage isolation switch to control a power transfer between two or more of the line voltage, the high voltage battery, or the low voltage battery.

8 . The system of claim 6 , wherein the one or more controllers are further configured to control an operation of the one or more of the primary transformer isolation switch, the high voltage isolation switch, or the low voltage isolation switch based on a fault status of one or more of the AC-DC converter, the high voltage buck-boost converter, or the low voltage buck-boost converter.

9 . The system of claim 1 , further comprising:

the high voltage battery connected to the DC-DC converter; and

the low voltage battery connected to the DC-DC converter,

wherein the system is provided as a bidirectional battery charger configured to:

receive input AC power from the line voltage through the AC-DC converter, convert the input AC power to output DC power, and supply the output DC power to charge one or more of the high voltage battery or the low voltage battery in a grid-to-battery operation, and

receive input DC power from one or more of the high voltage battery or the low voltage battery through the DC-DC converter, convert the input DC power to output AC power, and supply the output AC power to a load of the line voltage in a battery-to-grid operation.

10 . The system of claim 1 , further comprising:

an electric vehicle including the high voltage battery connected to the DC-DC converter.

11 . The system of claim 1 , wherein when the DC-DC converter is operating in (ii) the charging mode with the LV only buck operation, the high voltage buck-booster converter operates in a filter and pass mode, (iv) the HV to LV conversion mode with HV only buck operation, the low voltage buck-booster converter operates in a pass mode, and (v) the HV to LV conversion mode with no HV or LV buck operation, the high voltage buck-booster converter operates in the pass mode and the low voltage buck-booster converter operates in the pass mode.

12 . A system comprising:

a DC to DC converter (DC-DC converter) including:

a high voltage buck-boost converter having a secondary side connectable to a high voltage battery, the high voltage buck-boost converter including a first high voltage switch and a second high voltage switch, wherein the high voltage buck-boost converter is configured to operate in one or more modes, including at least one mode of the one or more modes where the first high voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second high voltage switch;

a low voltage buck-boost converter having a secondary side connectable to a low voltage battery, the low voltage buck-boost converter including a first low voltage switch and a second low voltage switch, wherein the low voltage buck-boost converter is configured to operate in one or more modes, including at least one mode of the one or more modes where the first low voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second low voltage switch; and

one or more transformers having a primary side connectable to an AC-DC converter, a secondary side connected to a primary side of the high voltage buck-boost converter, and a tertiary side connected to a primary side of the low voltage buck-boost converter; and

one or more controllers configured to control an operation of the high voltage buck-boost converter and the low voltage buck-boost converter to control a power transfer between two or more of a line voltage, the high voltage battery, or the low voltage battery;

wherein the one or more controllers control an operation of the first high voltage switch, the second high voltage switch, the first low voltage switch, and the second low voltage switch to configure the DC-DC converter into each of (i) a charging mode with both an HV and LV buck operation, (ii) a charging mode with an LV only buck operation, wherein the first high voltage switch is in the closed state and the second high voltage switch is in the open state, (iii) an HV to LV conversion mode with HV and LV buck operation, (iv) an HV to LV conversion mode with HV only buck operation, wherein the first low voltage switch is in the closed state and the second low voltage switch is in the open state, and (v) an HV to LV conversion mode with no HV or LV buck operation, wherein the first high voltage switch is in the closed state, the second high voltage switch is in the open state, the first low voltage switch is in the closed state, and the second low voltage switch is in the open state.

13 . The system of claim 12 , wherein the one or more controllers are further configured to control an operation of the DC-DC converter to control a power transfer between two or more of the AC-DC converter, the high voltage battery, or the low voltage battery.

14 . A method for controlling a system including a DC-DC converter including one or more transformers, a high voltage buck-boost converter including a first high voltage switch and a second high voltage switch, and a low voltage buck-boost converter including a first low voltage switch and a second low voltage switch, the method comprising performing, by one or more controllers, operations including:

controlling an operation of the high voltage buck-boost converter and the low voltage buck-boost converter to control a power transfer through the one or more transformers and one or more of the high voltage buck-boost converter or the low voltage buck-boost converter,

wherein the operations further include:

controlling the high voltage buck-boost converter to operate in one or more modes, including at least one mode of the one or more modes where the first high voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second high voltage switch,

controlling the low voltage buck-boost converter to operate in one or more modes, including at least one mode of the one or more modes where the first low voltage switch is configured to be in an open/closed state that is different from an open/closed state of the second low voltage switch, and

controlling an operation of one or more switches of the DC-DC converter to configure the DC-DC converter into each of (i) a charging mode with both an HV and LV buck operation, (ii) a charging mode with an LV only buck operation, wherein the first high voltage switch is in the closed state and the second high voltage switch is in the open state, (iii) an HV to LV conversion mode with HV and LV buck operation, (iv) an HV to LV conversion mode with HV only buck operation, wherein the first low voltage switch is in the closed state and the second low voltage switch is in the open state, and (v) an HV to LV conversion mode with no HV or LV buck operation.

15 . The method of claim 14 , wherein the operations further include:

controlling an operation of a bridge driver of the DC-DC converter to operate in each of a half-bridge driver configuration and in a full-bridge driver configuration, and

controlling the operation of the high voltage buck-boost converter and the low voltage buck-boost converter based on the operation of the bridge driver.

16 . The method of claim 14 , wherein the operations further include:

controlling the operation of the high voltage buck-boost converter and the low voltage buck-boost converter based on one or more of a voltage of a line voltage connected to the DC-DC converter, a battery connected to the DC-DC converter, or a power requirement of the DC-DC converter.

17 . The method of claim 14 , wherein the operations further include:

controlling the operation of the high voltage buck-boost converter and the low voltage buck-boost converter to operate the DC-DC converter in a capacitor pre-charge operation.

Assignments (2)

Continuity (1)

References Cited (14)