Bi-directional DC-DC converter
A bi-directional DC-DC converter and an on-board charger with the bi-directional DC-DC converter integrated into it are disclosed for converting a first voltage to a second voltage. The bi-directional DC-DC converter includes a transformer for magnetically coupling a primary circuit receiving the first voltage on a primary side with a rectification circuit on a secondary side. Further, a high voltage power source is connected to the rectification circuit for supplying a high voltage to one or more high voltage loads and a low voltage power source is connected to the high voltage power source through a secondary circuit for supplying a second voltage to one or more low voltage loads. The bi-directional DC-DC converter functions in both stationary condition and running condition of a powered device.
1 . A bi-directional DC-DC converter for converting a first voltage to a second voltage, comprising:
a primary circuit electrically receiving a first voltage;
a transformer for magnetically coupling the primary circuit on a primary side with a rectification circuit on a secondary side;
a high voltage power source electrically connected to the rectification circuit for supplying a high voltage to one or more high voltage loads; and
a low voltage power source electrically coupled to the high voltage power source through a secondary circuit for supplying a second voltage to one or more low voltage loads,
wherein the rectification circuit comprises a plurality of diodes,
wherein a filter circuit electrically connects the secondary side of the transformer to the high voltage power source, and
wherein the secondary circuit comprises at least one of:
a gating circuit electrically connecting the high voltage power source to the low voltage power source; and
a bridge circuit magnetically coupled to the primary circuit and the rectification circuit.
2 . The bi-directional DC-DC converter of claim 1 ,
wherein the rectification circuit further comprises a plurality of switches, and
wherein the bridge circuit of the secondary circuit electrically connects the high voltage power source to the low voltage power source.
3 . The bi-directional DC-DC converter of claim 1 , wherein the primary circuit comprises a full bridge configuration of switches electrically connected to a DC voltage source.
4 . The bi-directional DC-DC converter of claim 1 , wherein a control unit controls the primary circuit, the rectification circuit, and the secondary circuit for one of connecting and disconnecting the low voltage power source from the high voltage power source, based on battery parameters of the low voltage power source and the high voltage power source.
5 . The bi-directional DC-DC converter of claim 1 ,
wherein the bi-directional DC-DC converter is employed in an on-board charger of a powered device, and
wherein the bi-directional DC-DC converter is operational during at least one of a stationary condition of the powered device and a running condition of the powered device.
6 . The bi-directional DC-DC converter of claim 5 ,
wherein the on-board charger, further comprises a rectifier electrically connected to an AC power supply for converting a AC power supply voltage to a DC voltage, and
wherein a power factor correction stage electrically connected to the rectifier for generating the first voltage from the DC voltage.
7 . A method of converting a first voltage to a second voltage in an on-board charger comprises:
connecting a control unit and a bi-directional DC-DC converter, the bi-directional DC-DC converter comprising:
a primary circuit configured to electrically receive a first voltage;
a transformer configured to magnetically couple the primary circuit on a primary side with a rectification circuit on a secondary side;
a high voltage power source configured to electrically connect to the rectification circuit for supplying a high voltage to one or more high voltage loads; and
a low voltage power source configured to electrically couple to the high voltage power source through a secondary circuit for supplying a second voltage to one or more low voltage loads,
determining availability of the first voltage by the control unit;
sensing battery parameters of the high voltage power source and the low voltage power source by the control unit, based on the availability of the first voltage; and
applying a gating signal by the control unit to one or more of the primary circuit, the rectification circuit, and the secondary circuit, based on the sensed battery parameters, for converting the first voltage to the high voltage and the second voltage.
8 . The method of claim 7 ,
wherein for converting the first voltage to the high voltage comprises applying the gating signal to the primary circuit based on the sensed battery parameters of the high voltage power source, and
wherein for converting the high voltage to the second voltage comprises determining availability of the low voltage power source and applying the gating signal to the rectification circuit and the secondary circuit, based on the sensed battery parameters of the high voltage power source and the low voltage power source.
9 . The method of claim 7 ,
wherein for converting the first voltage to the high voltage based on the sensed battery parameters of the high voltage power source comprises determining availability of the low voltage power source and applying the gating signal to the primary circuit, the rectification circuit, and the secondary circuit, and
wherein for converting the high voltage to the second voltage comprises determining availability of the low voltage power source and applying the gating signal to the rectification circuit and the secondary circuit, based on the sensed battery parameters of the high voltage power source and the low voltage power source.