US 12,294,294 B2
Integrated on-board charger and auxiliary power module using a triple active bridge for electric vehicles
Liyan Zhu, Knoxville, TN (US); Alan W. Brown, Canton, MI (US); Hua Bai, Knoxville, TN (US); and Lukas Michael Keuck, Paderborn (DE)
Assigned to Hella Corporate Center USA, Inc., Northville, MI (US); and University of Tennessee Research Foundation, Knoxville, TN (US)
Appl. No. 17/928,006
Filed by Hella Corporate Center USA, Inc., Northville, MI (US); and University of Tennessee Research Foundation, Knoxville, TN (US)
PCT Filed May 25, 2021, PCT No. PCT/US2021/033986
§ 371(c)(1), (2) Date Nov. 28, 2022,
PCT Pub. No. WO2021/247278, PCT Pub. Date Dec. 9, 2021.
Claims priority of provisional application 63/033,246, filed on Jun. 2, 2020.
Prior Publication US 2023/0223840 A1, Jul. 13, 2023
Int. Cl. H02M 3/335 (2006.01); B60L 1/00 (2006.01); B60L 53/22 (2019.01); B60L 58/20 (2019.01); H02M 1/42 (2007.01); H02M 7/00 (2006.01); H02M 7/219 (2006.01); H02M 7/86 (2006.01); H02M 1/10 (2006.01)
CPC H02M 1/4208 (2013.01) [B60L 1/00 (2013.01); B60L 53/22 (2019.02); B60L 58/20 (2019.02); H02M 3/33561 (2013.01); H02M 7/003 (2013.01); H02M 7/219 (2013.01); H02M 7/86 (2013.01); B60L 2210/10 (2013.01); B60L 2240/527 (2013.01); B60L 2240/529 (2013.01); B60L 2270/147 (2013.01); H02M 1/10 (2013.01); H02M 1/4216 (2013.01); H02M 1/4233 (2013.01); H02M 3/33573 (2021.05); H02M 3/33584 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A power conversion system comprising:
a power factor correction module including a power factor correction rectifier, the power factor correction rectifier being adapted to convert a single-phase AC or a three-phase AC into a voltage regulated DC-bus voltage; and
a three-port converter module including a voltage-fed primary-side full bridge, a current-fed on-board charger full bridge, and a current-fed auxiliary power module full bridge, the three-port converter including a three-winding transformer having a first winding electrically connected to the primary-side full-bridge, a second winding electrically connected to the on-board charger full-bridge, and a third winding electrically connected to the auxiliary power module full-bridge, thereby forming a triple-active-bridge;
wherein the primary-side full bridge is electrically connected to the DC-bus voltage, the on-board charger full-bridge is adapted to convert an AC output of the second winding into a first DC voltage at a first output port, and the auxiliary power module full-bridge is adapted to convert an AC output of the third winding into a second DC voltage at a second output port, the first DC voltage being greater than the second DC voltage, the three-port converter module further including:
a first switch adapted to switch between a voltage-fed output and a current-fed output at the first output port, the first switch including a first input terminal, a second input terminal, and an output terminal, the output terminal being coupled to the first output port,
a first clamp capacitor that is parallel-connected to the first output port via the first input terminal when the first switch provides the voltage-fed output to the first output port, and
a first low-pass filter that is coupled to the first output port via the second input terminal when the first switch provides the current-fed output to the first output port,
such that the three-port converter module comprises a dual output DC-DC converter that is operable to provide the first DC voltage to the first output port while simultaneously providing the second DC voltage to the second output port, the first DC voltage being either of the voltage-fed output or the current-fed output.