Systems and methods for configurable DC-DC converter and battery charger
A system for a direct current (DC) to DC converter, the system comprising one or more transformers, a bridge driver connected to a primary side of the one or more transformers, a first bridge rectifier connected to a secondary side of the one or more transformers, a second bridge rectifier connected to a 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 (DC-DC converter), the system comprising:
one or more transformers;
a bridge driver connected to a primary side of the one or more transformers;
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;
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; and
a controller 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 when a sensed voltage of a battery connected to the DC-DC converter is in a low voltage region, to configure the first bridge rectifier and the second bridge rectifier in the parallel rectifier configuration when the sensed voltage is in a nominal voltage region, and to configure the first bridge rectifier and the second bridge rectifier in the series rectifier configuration when the sensed voltage is in a full voltage region.
2. The system of claim 1 , wherein the one or more secondary configuration switches include a first secondary configuration switch, a second secondary configuration switch, and a third secondary configuration switch.
3. The system of claim 2 , 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.
4. The system of claim 2 , 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.
5. The system of claim 2 , 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.
6. The system of claim 1 , wherein the controller is further configured to control the operation of the bridge driver to operate into each of a half-bridge driver configuration and in a full-bridge driver configuration.
7. The system of claim 1 , wherein the controller is further configured to turn off switches of the second bridge rectifier in the single rectifier configuration.
8. The system of claim 1 , wherein the DC-DC converter has a voltage operating range from approximately 170V to approximately 850V at a battery interface connected to the first bridge rectifier and the second bridge rectifier.
9. 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.
10. The system of claim 9 , further comprising:
a battery connected to the DC-DC converter of the battery charger.
11. The system of claim 10 , 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.
12. The system of claim 1 , wherein the one or more transformers include one or more high-frequency transformers provided in a resonant tank including one or more of a multiple winding transformer or multiple transformers.
13. A method for controlling a system including a direct current (DC) to DC converter (DC-DC converter) including one or more transformers, a bridge driver, 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 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,
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.
14. The method of claim 13 , 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 rectifier and the second bridge rectifier in the single rectifier configuration when the sensed voltage is in a low voltage region, to configure the first bridge rectifier and the second bridge rectifier in the parallel rectifier configuration when the sensed voltage is in a nominal voltage region, and to configure the first bridge rectifier and the second bridge rectifier in the series rectifier configuration when the sensed voltage is in a full voltage region.
15. The method of claim 13 , wherein the operations further include controlling the operation of the bridge driver to operate in each of a half-bridge driver configuration and in a full-bridge driver configuration.
16. The method of claim 13 , 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.
17. 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 secondary configuration switches to configure a first bridge rectifier and a second bridge rectifier of a direct current (DC) to DC converter (DC-DC converter) into each of a single rectifier configuration, a parallel rectifier configuration, and a series rectifier configuration,
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.
18. The non-transitory computer readable medium of claim 17 , wherein the operations further include: controlling the 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.
19. The non-transitory computer readable medium of claim 17 , 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 further includes: turning off switches of the second bridge rectifier.
20. A method for controlling a system including a direct current (DC) to DC converter (DC-DC converter) including one or more transformers, a bridge driver, 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 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; and
controlling the operation of the bridge driver to operate in each of a half-bridge driver configuration and in a full-bridge driver configuration.