Abstract:
A multi-level DC-DC converter device includes an inverter, a 3-winding high-frequency transformer, a first full-bridge rectifier, a second full-bridge rectifier, a selective circuit and a filter circuit. A first winding at a primary side of the high-frequency transformer connects with the inverter while a second winding and a third winding of at a secondary side of the high-frequency transformer connect with the first full-bridge rectifier and the second full-bridge rectifier. The selective circuit connects with DC output ports of the first full-bridge rectifier and the second full-bridge rectifier, thereby operationally selecting two serially-connected full-bridge rectifiers or single full-bridge rectifier to output two voltage levels performed as a multi-level output voltage. The filter circuit connects between the selective circuit and a load for filtering harmonics and outputting a DC voltage.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a unidirectional isolated multi-level DC-DC converter and control method thereof. Particularly, the present invention relates to the unidirectional isolated multi-level DC-DC converter and control method thereof for reducing the dimensions. More particularly, the present invention relates to the unidirectional isolated multi-level DC-DC converter and control method thereof for minimizing a ripple quantity of output voltages and output currents. 
         [0003]    2. Description of the Related Art 
         [0004]    Generally, a conventional isolated DC-DC converter has been widely used in various industrial fields. Even though the conventional isolated DC-DC converter has a specific advantageous of simple and easy control, it has several drawbacks in operation, including low efficiencies, high ripple quantities, high electromagnetic interference and requiring the use of a filter circuit with a large capacity. Conversely, a conventional multi-level DC-DC converter has several advantageous of relatively higher efficiencies, relatively lower electromagnetic interference and allowing the use of a filter circuit with a relatively lower capacity even though it has a drawback of requiring sophisticated control. 
         [0005]    For example,  FIG. 1  shows a schematic view of a conventional multi-level DC-DC converter in accordance with the prior art. Referring initially to  FIG. 1 , the multi-level DC-DC converter  1  includes a dual half-bridge inverter  11 , a dual high-frequency transformer  12 , a full-bridge rectifier  13  and an output filter circuit  14  which are combined to form the multi-level DC-DC converter  1 . In addition, the dual half-bridge inverter  11  must be constructed with four power switches and four capacitors. 
         [0006]    With continued reference to  FIG. 1 , the dual half-bridge inverter  11  is formed from two separate half-bridge inverters serially connected. The dual high-frequency transformer  12  includes two high-frequency transformers each of which connects with an AC end of each half-bridge inverter of the dual half-bridge inverter  11 . In power conversion operation, the power switches of the dual half-bridge inverter  11  are controllably switched such that the dual high-frequency transformer  12  can generate three levels of voltages at its primary side. Furthermore, the full-bridge rectifier  13  is utilized to rectify the three levels of voltages to thereby generate two voltage levels at a secondary side of the dual high-frequency transformer  12 . 
         [0007]    Disadvantageously, the two half-bridge inverters of the dual half-bridge inverter  11  require a sophisticated control manner and an arrangement of the four capacitors. However, the four capacitors may possess four different capacitances which may result in different voltages of the four capacitors and requiring more sophisticated control manner. In addition, the two high-frequency transformers of the dual high-frequency transformer  12  require using two iron cores which will result in increasing of manufacturing cost and dimensions. 
         [0008]    However, there is a need of improving the conventional multi-level DC-DC converter and conversion method thereof. The above-mentioned prior art is incorporated herein by reference for purposes including, but not limited to, indicating the background of the present invention and illustrating the situation of the art. 
         [0009]    As is described in greater detail below, the present invention provides a unidirectional isolated multi-level DC-DC converter and control method thereof. The unidirectional isolated multi-level DC-DC converter is formed with an inverter, a 3-winding high-frequency transformer, a first full-bridge rectifier, a second full-bridge rectifier, a selection circuit and a filter circuit. Only one of inverter and one of high-frequency transformer is provided to simplify a structure of the unidirectional isolated multi-level DC-DC converter. The selection circuit is provided to generate a low-harmonic pulse voltage to the filter circuit to thereby allow using a low capacity of the filter circuit in such a way as to overcome the problems of the conventional multi-level DC-DC converter and conversion method thereof multi-level DC-DC converter and conversion method thereof. 
       SUMMARY OF THE INVENTION 
       [0010]    The primary objective of this invention is to provide a unidirectional isolated multi-level DC-DC converter and control method thereof. The unidirectional isolated multi-level DC-DC converter is formed with an inverter, a 3-winding high-frequency transformer, a first full-bridge rectifier, a second full-bridge rectifier, a selection circuit and a filter circuit. Only one of inverter and one of high-frequency transformer is provided to simplify a structure of the unidirectional isolated multi-level DC-DC converter. The selection circuit is further provided to generate a low-harmonic pulse voltage to the filter circuit to thereby allow using a low capacity of the filter circuit. Advantageously, the unidirectional isolated multi-level DC-DC converter and conversion method of the present invention is successful in minimizing the dimensions, reducing the manufacturing cost and enhancing the operational efficiency. 
         [0011]    The unidirectional isolated multi-level DC-DC converter in accordance with an aspect of the present invention includes: 
         [0012]    an inverter connected with a power source, with the inverter including an AC output end from which to generate a fixed pulse-width high-frequency AC voltage; 
         [0013]    a 3-winding high-frequency transformer including a primary side and a secondary side, with the primary side having a first winding, with the first winding connecting with the AC output end of the inverter, with the secondary side having a second winding and a third winding; 
         [0014]    a first full-bridge rectifier including a first input end connected with the second winding of the secondary side of the 3-winding high-frequency transformer, with the first full-bridge rectifier further including a first DC positive output end and a first DC negative output end of a first DC output port, with the first DC positive output end and the first DC negative output end connecting with a first capacitor in parallel to generate a first output DC voltage; 
         [0015]    a second full-bridge rectifier including a second input end connected with the third winding of the secondary side of the 3-winding high-frequency transformer, with the second full-bridge rectifier further including a second DC positive output end and a second DC negative output end of a second DC output port, with the second DC positive output end and the second DC negative output end connecting with a second capacitor in parallel to generate a second output DC voltage, with the second DC positive output end of the second full-bridge rectifier further connected with the first DC negative output end of the first full-bridge rectifier; 
         [0016]    a selection circuit including a first input end, a second input end and an output end, with the first input end of the selection circuit connected with the first DC positive output end of the first full-bridge rectifier, with the second input end of the selection circuit connected with the second DC positive output end of the second full-bridge rectifier; and 
         [0017]    a filter circuit connected with the output end of the selection circuit and the second DC negative output end of the second full-bridge rectifier. 
         [0018]    In a separate aspect of the present invention, the inverter is selected from a half-bridge inverter or a full-bridge inverter. 
         [0019]    In a further separate aspect of the present invention, a DC output voltage of the selection circuit is controllably identical with a first voltage which is a sum of the first output DC voltage and the second output DC voltage or a second voltage which is the second output DC voltage minus a voltage drop, thereby outputting a multi-level DC output voltage varied from the first voltage to the second voltage and further supplying the DC output voltage via the filter circuit. 
         [0020]    In yet a further separate aspect of the present invention, the voltage drop is generated from a diode. 
         [0021]    In yet a further separate aspect of the present invention, the selection circuit includes a power electronic switch and a diode, with the power electronic switch connected between the first input end and the output end of the selection circuit. 
         [0022]    In yet a further separate aspect of the present invention, the diode includes an anode and a cathode, with the anode connecting with the second input end of the selection circuit and the cathode connecting with the output end of the selection circuit. 
         [0023]    In yet a further separate aspect of the present invention, a power electronic switch of the selection circuit controls a DC output voltage of the selection circuit controllably identical with a first voltage which is a sum of the first output DC voltage and the second output DC voltage or a second voltage which is the second output DC voltage minus a voltage drop, thereby outputting a multi-level DC output voltage varied from the first voltage to the second voltage and further supplying the DC output voltage via the filter circuit. 
         [0024]    In yet a further separate aspect of the present invention, the filter circuit includes an inductor and a capacitor. 
         [0025]    The control method of the unidirectional isolated multi-level DC-DC converter in accordance with an aspect of the present invention includes: 
         [0026]    providing an inverter, a 3-winding high-frequency transformer, a first full-bridge rectifier, a second full-bridge rectifier, a selection circuit and a filter circuit, with the selection circuit including a first input end, a second input end and an output end; 
         [0027]    connecting the inverter with a power source, with the inverter including an AC output end from which to generate a fixed pulse-width high-frequency AC voltage; 
         [0028]    providing a first winding at a primary side of the 3-winding high-frequency transformer and providing a second winding and a third winding at a secondary side of the 3-winding high-frequency transformer, with the first winding connecting with the AC output end of the inverter; 
         [0029]    connecting a first input end of the first full-bridge rectifier with the second winding of the secondary side of the 3-winding high-frequency transformer, with the first full-bridge rectifier further including a first DC positive output end and a first DC negative output end of a first DC output port, with the first DC positive output end and the first DC negative output end connecting with a first capacitor in parallel to generate a first output DC voltage; 
         [0030]    connecting a second input end of the second full-bridge rectifier with the third winding of the secondary side of the 3-winding high-frequency transformer, with the second full-bridge rectifier further including a second DC positive output end and a second DC negative output end of a second DC output port, with the second DC positive output end and the second DC negative output end connecting with a second capacitor in parallel to generate a second output DC voltage, with the second DC positive output end of the second full-bridge rectifier further connected with the first DC negative output end of the first full-bridge rectifier; 
         [0031]    connecting the first input end of the selection circuit with the first DC positive output end of the first full-bridge rectifier and connecting the second input end of the selection circuit with the second DC positive output end of the second full-bridge rectifier; and 
         [0032]    connecting the filter circuit with the output end of the selection circuit and the second DC negative output end of the second full-bridge rectifier; 
         [0033]    controlling a DC output voltage of the selection circuit controllably identical with a first voltage which is a sum of the first output DC voltage and the second output DC voltage or a second voltage which is the second output DC voltage minus a voltage drop, thereby outputting a multi-level DC output voltage varied from the first voltage to the second voltage and further supplying the DC output voltage via the filter circuit. 
         [0034]    In a separate aspect of the present invention, the voltage drop is generated from a diode. 
         [0035]    In a further separate aspect of the present invention, the inverter is selected from a half-bridge inverter or a full-bridge inverter. 
         [0036]    In yet a further separate aspect of the present invention, the selection circuit includes a power electronic switch and a diode, with the power electronic switch connected between the first input end and the output end of the selection circuit. 
         [0037]    In yet a further separate aspect of the present invention, the diode includes an anode and a cathode, with the anode connecting with the second input end of the selection circuit and the cathode connecting with the output end of the selection circuit. 
         [0038]    In yet a further separate aspect of the present invention, a power electronic switch of the selection circuit controls a DC output voltage of the selection circuit controllably identical with a first voltage which is a sum of the first output DC voltage and the second output DC voltage or a second voltage which is the second output DC voltage minus a voltage drop, thereby outputting a multi-level DC output voltage varied from the first voltage to the second voltage and further supplying the DC output voltage via the filter circuit. 
         [0039]    In yet a further separate aspect of the present invention, the filter circuit includes an inductor and a capacitor. 
         [0040]    Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various will become apparent to those skilled in the art from this detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0041]    The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein: 
           [0042]      FIG. 1  is a schematic view of a conventional multi-level DC-DC converter in accordance with the prior art. 
           [0043]      FIG. 2  is a schematic view of a unidirectional isolated multi-level DC-DC converter in accordance with a first preferred embodiment of the present invention. 
           [0044]      FIG. 3(A)  is a schematic view of a half-bridge inverter applied in the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention. 
           [0045]      FIG. 3(B)  is a schematic view of a full-bridge inverter applied in the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention. 
           [0046]      FIG. 4  is a schematic view of the unidirectional isolated multi-level DC-DC converter in accordance with a second preferred embodiment of the present invention. 
           [0047]      FIGS. 5( a )-5( c )  are a series of waveform diagrams of signals of power switches and a waveform diagram of multi-level output voltage applied in a control method of the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0048]    It is noted that a unidirectional isolated multi-level DC-DC converter, operation method and control method thereof in accordance with the preferred embodiment of the present invention can be applicable to various multi-level DC-DC converters or other equivalent devices, which are not limitative of the present invention. 
         [0049]      FIG. 2  shows a schematic view of a unidirectional isolated multi-level DC-DC converter in accordance with a first preferred embodiment of the present invention. Referring now to  FIG. 2 , the unidirectional isolated multi-level DC-DC converter  2  in accordance with the first preferred embodiment of the present invention includes an inverter  21 , a 3-winding high-frequency transformer  22 , a first full-bridge rectifier  23 , a second full-bridge rectifier  24 , a selection circuit  25  and a filter circuit  27 . The selection circuit  25  further includes a first input end, a second input end and an output end. 
         [0050]    With continued reference to  FIG. 2 , by way of example, the inverter  21  is selected from a half-bridge inverter or a full-bridge inverter. In  FIG. 3(A) , a type of half-bridge inverter suitable for use in the unidirectional isolated multi-level DC-DC converter  2  is shown. The half-bridge inverter includes two power electronic switches and two capacitors connected thereto. In  FIG. 3(B) , a type of full-bridge inverter suitable for use in the unidirectional isolated multi-level DC-DC converter  2  is shown. The half-bridge inverter includes four power electronic switches and a capacitor connected thereto. The inverter  21  includes a DC input end at a first side and an AC output end at a second side. The DC input end of the inverter  21  further connects with a DC power source  28  in parallel for power inversion, as best shown in the left portion in  FIG. 2 . In addition, the AC output end of the inverter  21  is configured to supply a fixed pulse-width high-frequency AC voltage. 
         [0051]    With continued reference to  FIG. 2 , by way of example, the 3-winding high-frequency transformer  22  has a primary side and a secondary side and includes a first winding  220  provided at the primary side, a second winding  221  and a third winding  222  provided at the secondary side. The first winding  220  connects with the AC output end of the inverter  21 . Furthermore, the filter circuit  27  includes an inductor  271  and a capacitor  272  connected thereto, as best shown in the right portion in  FIG. 2 . 
         [0052]    With continued reference to  FIG. 2 , by way of example, the first full-bridge rectifier  23  includes diodes D 1 , D 2 , D 3 , D 4  connected in full bridge formation. A first AC input end of the first full-bridge rectifier  23  connects with the second winding  221  of the secondary side of the 3-winding high-frequency transformer  22 . The first full-bridge rectifier  23  further includes a first DC positive output end and a first DC negative output end of a first DC output port which further connects with a first capacitor  261  in parallel to generate a first output DC voltage. 
         [0053]    With continued reference to  FIG. 2 , by way of example, the second full-bridge rectifier  24  includes diodes D 5 , D 6 , D 7 , D 8  connected in full bridge formation. A second input end of the second full-bridge rectifier  24  connects with the third winding  222  of the secondary side of the 3-winding high-frequency transformer  22 . The second full-bridge rectifier  24  further includes a second DC positive output end and a second DC negative output end of a second DC output port which further connects with a second capacitor in parallel to generate a second output DC voltage. In addition, the second DC positive output end of the second full-bridge rectifier further connected with the first DC negative output end of the first full-bridge rectifier. 
         [0054]    With continued reference to  FIG. 2 , by way of example, the selection circuit  25  includes a power electronic switch  251  and a diode  252  connected thereto. The power electronic switch  251  is provided between the first input end and the output end of the selection circuit  25 . A first end of the power electronic switch  251  connects with the first DC positive output end of the first full-bridge rectifier  23 , thereby forming the first input end of the selection circuit  25 . The diode  252  includes an anode and a cathode. The anode of the diode  252  connects with the second DC positive output end of the second full-bridge rectifier  24 , thereby forming the second input end of the selection circuit  25 . A second end of the power electronic switch  251  connects with the cathode of the diode  252 , thereby forming the output end of the selection circuit  25 . 
         [0055]    With continued reference to  FIG. 2 , by way of example, the power electronic switch  251  of the selection circuit  25  controls a DC output voltage of the selection circuit  25  controllably identical with a first voltage which is a sum of the first output DC voltage of the first full-bridge rectifier  23  and the second output DC voltage of the second full-bridge rectifier  24  or a second voltage which is the second output DC voltage of the second full-bridge rectifier  24  minus a predetermined voltage drop (or other voltage drop values), thereby outputting a multi-level DC output voltage varied from the first voltage to the second voltage and further supplying a DC voltage V out  at an output end  29  via the filter circuit  27 . 
         [0056]      FIG. 3(A)  shows a schematic view of a half-bridge inverter applied in the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention. Similarly,  FIG. 3(B)  further shows a schematic view of a full-bridge inverter applied in the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention. 
         [0057]      FIG. 4  shows a schematic view of the unidirectional isolated multi-level DC-DC converter in accordance with a second preferred embodiment of the present invention. Referring to  FIG. 4 , in comparison with the first embodiment, the inverter  21  of the second preferred embodiment includes an upper power electronic switch S 1 , a lower power electronic switch S 2  and two capacitors C 1 , C 2 . 
         [0058]      FIGS. 5( a )-5( c )  are a series of waveform diagrams of signals of power switches and a waveform diagram of multi-level output voltage applied in a control method of the unidirectional isolated multi-level DC-DC converter in accordance with the preferred embodiment of the present invention, corresponding to that shown in  FIG. 4 . Referring to  FIGS. 4 and 5 (A), the upper power electronic switch S 1  and the lower power electronic switch S 2  of the inverter  21  are alternatively switched by a fixed duty cycle of 0.5. Accordingly, the inverter  21  can supply a fixed-pulse-width high-frequency square-wave voltage to the first winding  220  of the 3-winding high-frequency transformer  22 . Synchronously, the second winding  221  and the third winding  222  of the 3-winding high-frequency transformer  22  are inducted to thereby generate high-frequency square-wave voltages with an identical waveform. Further, the high-frequency square-wave voltages are passed through the first full-bridge rectifier  23  and the second full-bridge rectifier  24  to generate the first output DC voltage and the second output DC voltage, respectively. Suppose an input DC voltage is Vin and the first winding, second winding and third winding has turns ratio n1:n2:n3. The first output DC voltage is Vin*n2/n1 and the second output DC voltage is Vin*n3/n1. The first output DC voltage is Vin*n2/n1 may be equal to or less than the second output DC voltage minus the voltage of the diode  252 .  FIG. 5(B)  show a waveform diagram of signals of the power electronic switch  251  of the selection circuit  25 . By way of example, the signals of the power electronic switch  251  of the selection circuit  25  has a frequency of switching which is two times or may be increased by more times of that of the high-frequency square-wave voltage of the inverter  21 , as best shown in  FIGS. 5(A) and 5(B) . 
         [0059]    Referring again to  FIGS. 4 and 5 (A) to  5 (C), when the power electronic switch  251  of the selection circuit  25  is switched on, the first output DC voltage and the second output DC voltage are serially connected to supply power. Consequently, the output voltage of the selection circuit  25  is a sum of the first output DC voltage and the second output DC voltage (Vin*n2/n1+Vin*n3/n1). Conversely, when the power electronic switch  251  of the selection circuit  25  is switched off, the second output DC voltage of the second full-bridge rectifier  24  must pass through the diode  252  to supply power. Consequently, the output voltage of the selection circuit  25  is the second output DC voltage of the second full-bridge rectifier  24  (Vin*n3/n1). The selection circuit  25  can supply two-level voltages to the filter circuit  27  to generate a DC voltage to a load (not shown). The DC voltage (Vin*n2/n1+Vin*n3/n1) must be higher than that supplied to the load and the DC voltage (Vin*n3/n1) must be lower than that supplied to the load. 
         [0060]    The conventional isolated DC-DC converter supplies a zero voltage and a two-level DC voltage higher than that supplied to the load. However, the unidirectional isolated multi-level DC-DC converter of the present invention can supply the filter circuit  27  with the DC voltage relatively smaller than that of the conventional isolated DC-DC converter which results in smaller harmonic. Advantageously, the capacity of the filter circuit  27  can be reduced to compact dimensions, to lower manufacturing cost and to enhance operational efficiency. 
         [0061]    Although the invention has been described in detail with reference to its presently preferred embodiment, it will be understood by one of ordinary skills in the art that various modifications can be made without departing from the spirit and the scope of the invention, as set forth in the appended claims.