Abstract: In at least one embodiment, a power conversion device for a vehicle is provided. The power conversion device includes a transformer, a microcontroller, and a control circuit. The microcontroller is configured to operate at a first frequency to receive a first current signal indicative of a current of a first voltage network and to generate a first envelope control signal in response to the first current signal. The controller is configured to selectively switch a first plurality of switches on a primary side and a second plurality of switches on a secondary side to convert a first input signal into first output signal in response to at least the first envelope control signal. The controller is further configured to selectively switch the first plurality of switches and the second plurality of switches at a second frequency that is greater than the first frequency.

Abstract: An on-board charger for charging a battery, such as a traction battery of an electric vehicle, includes an AC/DC converter and a pulsating buffer (PB) converter. The AC/DC converter is configured to convert an AC input from a mains supply into an output having a DC voltage and a current ripple. The PB converter is connected to the AC/DC converter and is configured to process the output of the AC/DC converter to reduce or minimize the current ripple thereof and transform the output of the AC/DC converter into a battery-level DC output for charging the battery.

Abstract: In at least one embodiment, a power conversion device for a vehicle is provided. The power conversion device includes a transformer, a microcontroller, and a control circuit. The microcontroller is configured to operate at a first frequency to receive a first current signal indicative of a current of a first voltage network and to generate a first envelope control signal in response to the first current signal. The controller is configured to selectively switch a first plurality of switches on a primary side and a second plurality of switches on a secondary side to convert a first input signal into first output signal in response to at least the first envelope control signal. The controller is further configured to selectively switch the first plurality of switches and the second plurality of switches at a second frequency that is greater than the first frequency.

Abstract: An on-board charger (OBC) for using AC power to charge a traction battery of an electric vehicle includes a DC/DC converter and a controller. The converter receives input power including a voltage having a DC voltage component and a voltage ripple varying at a frequency of the AC power. The controller generates a control signal for controlling the converter to convert the input power into an output power having a current for charging the battery. The controller includes a filter which enhances a sensed value of the current at the frequency to generate a locally-enhanced sensed value of the current. The controller determines a difference between a target and the locally-enhanced sensed value of the current and generates the control signal based on the difference such that the converter in converting the input power into the output power in response to the control signal adapts the current to the target.

Abstract: Systems and methods for balancing phase currents of the phases of a multiphase converter include alternately connecting the phases during respective intervals to an input current and sampling, at a node of the multiphase converter that is common to the phases, the input current provided to the phases to obtain respective input current samples for the phases. While the input current samples are unequal, the intervals are adjusted to minimize inequality of the input current samples and thereby balance the phase currents.

Abstract: An on-board charger for charging a battery, such as a traction battery of an electric vehicle, includes an AC/DC converter and a pulsating buffer (PB) converter. The AC/DC converter is configured to convert an AC input from a mains supply into an output having a DC voltage and a current ripple. The PB converter is connected to the AC/DC converter and is configured to process the output of the AC/DC converter to reduce or minimize the current ripple thereof and transform the output of the AC/DC converter into a battery-level DC output for charging the battery.

Abstract: An on-board charger (OBC) for using AC power to charge a traction battery of an electric vehicle includes a DC/DC converter and a controller. The converter receives input power including a voltage having a DC voltage component and a voltage ripple varying at a frequency of the AC power. The controller generates a control signal for controlling the converter to convert the input power into an output power having a current for charging the battery. The controller includes a filter which enhances a sensed value of the current at the frequency to generate a locally-enhanced sensed value of the current. The controller determines a difference between a target and the locally-enhanced sensed value of the current and generates the control signal based on the difference such that the converter in converting the input power into the output power in response to the control signal adapts the current to the target.

Abstract: A power factor corrector (PFC), such as for an on-board charger (OBC) for charging a vehicle traction battery, uses an input voltage and an input current from a power source to output a desired voltage. The PFC has an inductor and first and second power switches. A micro-controller generates, for each half-cycle of the input voltage, first and second reference signals respectively indicative of (i) a sinusoidal envelope of the inductor current for which the PFC will absorb sufficient power from the power source for the PFC to output the desired voltage and (ii) a reverse value of the inductor current for which zero voltage switching (ZVS) of the switches is ensured. A comparator assembly turns the first switch off (on) and the second switch on (off) upon the inductor current equaling the outer sinusoidal amplitude envelope (the reverse value) whereby the PFC outputs the desired voltage with ZVS.

Abstract: In at least one embodiment, a transformer assembly is provided. The assembly includes a first printed circuit board (PCB), a magnetic core, a primary winding, and a secondary winding. The magnetic core is positioned about the first PCB. The primary winding is implemented as a wire assembly and is positioned on a first side of the PCB to interface with the magnetic core. The secondary winding is embedded within the first PCB to interface with the primary winding and the magnetic core to convert an input signal into a converted output signal.

Abstract: A power factor corrector (PFC), such as for an on-board charger (OBC) for charging a vehicle traction battery, uses an input voltage and an input current from a power source to output a desired voltage. The PFC has an inductor and first and second power switches. A micro-controller generates, for each half-cycle of the input voltage, first and second reference signals respectively indicative of (i) a sinusoidal envelope of the inductor current for which the PFC will absorb sufficient power from the power source for the PFC to output the desired voltage and (ii) a reverse value of the inductor current for which zero voltage switching (ZVS) of the switches is ensured. A comparator assembly turns the first switch off (on) and the second switch on (off) upon the inductor current equaling the outer sinusoidal amplitude envelope (the reverse value) whereby the PFC outputs the desired voltage with ZVS.

Abstract: Systems and methods for balancing phase currents of the phases of a multiphase converter include alternately connecting the phases during respective intervals to an input current and sampling, at a node of the multiphase converter that is common to the phases, the input current provided to the phases to obtain respective input current samples for the phases. While the input current samples are unequal, the intervals are adjusted to minimize inequality of the input current samples and thereby balance the phase currents.