Abstract: In at least one embodiment, a vehicle battery charger is provided. The charger includes at least one transformer, a first active bridge, a second active bridge, and at least one controller. The first active bridge includes a first plurality of switching devices being positioned with the primary. The second active bridge includes a second plurality of switching devices being positioned with the secondary to generate. The controller is configured to activate the first plurality of switching devices based on a primary control signal and to activate the second plurality of switching devices based on a secondary control signal. The controller is configured to generate the secondary control signal in accordance to a first control variable. The controller is further configured to generate a second control variable that corresponds to a phase shift between the primary control signal and the secondary control signal.

Abstract: In at least one embodiment, a battery charger is provided. The battery charger includes at least one transformer, a first active bridge, a second active bridge, and a pulsating buffer (PB) converter. The first active bridge is positioned on a first side of the transformer to provide a first voltage signal based on an input voltage signal from a mains supply of an electrical grid. The second active bridge is positioned on a second side of the transformer to provide a second voltage signal to store on one or more batteries based on the first voltage signal. The PB converter includes a plurality of switching devices to interface with the second active bridge to modify the second voltage signal. The plurality of switching devices provide a voltage for storage on at least one capacitor of the PB converter while modifying the second voltage signal.

Abstract: A DC/DC converter applies a dual active bridge (DAB) topology to convert an input DC voltage into an output DC voltage. The DC/DC converter includes a transformer, a primary stage, and a secondary stage. The primary stage includes an inductor, a first H-bridge arm having first and second power switches connected at a first node therebetween, and a second H-bridge arm having first and second capacitors connected at a second node therebetween. The inductor is connected between the first node and a terminal of an input port of the primary stage. The primary stage receives the input DC voltage at the input port of the primary stage and converts the input DC voltage into a first AC voltage. The transformer transforms the first AC voltage into a second AC voltage. The secondary stage converts the second AC voltage into the output DC voltage.

Abstract: In at least one embodiment, a power conversion device for a vehicle is provided. At least one controller is configured to selectively switch a first plurality of switches and a second plurality of switches to convert a first input signal into a first output signal. The at least one controller is further configured to receive a high voltage signal on a primary side and to receive a low voltage signal on the secondary side. The at least controller is further configured to generate a compensation factor based at least on the high voltage signal and the low voltage signal. The at least one controller is further configured to provide a first activation signal to control the switching of the first plurality of switches and the second plurality of switches based at least on the compensation factor.

Abstract: A DC-DC converter includes a first switching network that receives the input DC voltage and outputs a first AC voltage, a transformer, and a secondary side conversion circuit that receives the second AC voltage and outputs the output DC voltage. The transformer includes a first plurality of primary windings, a second plurality of primary windings and a plurality of secondary windings. The transformer is configured to receive the first AC voltage and outputting a second AC voltage. When the input DC voltage is intended to be used in a low voltage range, the first plurality of primary windings and the second plurality of primary windings are configured to be in parallel at the time the DC-DC converter is manufactured. When the input DC voltage is intended to be used in a high voltage range the first plurality of primary windings and the second plurality of primary windings are configured to be in series at the time of manufacture.

Abstract: A DC-DC converter includes a first switching network that receives an input DC voltage and outputs a first AC voltage, a transformer, and a secondary side conversion circuit. The first switching network receives an input DC voltage. The transformer includes a middle-point primary tap such that when the input DC voltage is in a low voltage range, the middle-point tap of the transformer primary is connected to the input DC voltage causing current to flow through the first plurality of primary windings in parallel to current flowing through the second plurality of primary windings and when the input DC voltage is in a high voltage range, the middle-point tap is disconnected from the input DC voltage causing current to flow through the first plurality of primary windings in series with current flowing through the second plurality of primary windings.

Abstract: In at least one embodiment, a vehicle battery charger is provided. At least one transformer includes a first winding and a second winding on a primary side of the transformer that are connected to one another to form a middle point. The middle point of the at least one transformer receives an input voltage signal from a mains supply. A half-bridge rectifier receives the input voltage signal from the mains supply to enable the middle point of the least one transformer to receive the input voltage signal from the mains supply. A first active bridge includes a first plurality of switching devices to receive a first input signal directly from the first winding and to receive a second input signal directly from the second winding. The first input signal and the second input signal are out of phase with one another to minimize electromagnetic interference within the vehicle battery charger.

Abstract: In at least one embodiment, a vehicle battery charger is provided. The charger includes at least one transformer, a first active bridge, a second active bridge, and at least one controller. The first active bridge includes a first plurality of switching devices being positioned with the primary. The second active bridge includes a second plurality of switching devices being positioned with the secondary to generate. The controller is configured to activate the first plurality of switching devices based on a primary control signal and to activate the second plurality of switching devices based on a secondary control signal. The controller is configured to generate the secondary control signal in accordance to a first control variable. The controller is further configured to generate a second control variable that corresponds to a phase shift between the primary control signal and the secondary control signal.

Abstract: A bidirectional or unidirectional DC-DC converter includes a primary stage and a secondary stage. The primary stage is configured to receive or output a first DC voltage. The primary stage includes a first switching network configured to convert the first DC voltage to a first alternating current (AC) voltage or vice versa. The DC-DC converter also includes a transformer having primary windings and secondary windings. The primary windings are in electrical communication with the first switching network. The transformer is configured to convert between the first AC voltage and a second AC voltage. The DC-DC converter also includes a secondary stage that has a second switching network. Characteristically, the second switching network and the transformer operate as an interleaved converter to convert the second AC voltage to an output DC voltage or vice versa. Advantageously, the required series inductance for this interleaved converter is integrated into the transformer.

Abstract: In at least one embodiment, an apparatus including a pulse buffer (PB) converter. The PB converter including a housing, a printed circuit board (PCB), at least one inductor, and at least one capacitor is provided. The PCB is positioned in the housing and includes at least one first power switch and at least one second power switch positioned thereon. The at least one inductor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least second power switch. The at least one capacitor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least one second power switch to regulate an energy output to one or more vehicle batteries during a charging operation.

Abstract: A DC-DC converter that converts an input DC voltage to an output DC voltage includes a first switching network, a first transformer component, a second transformer, a first secondary side rectifier circuit, and a second secondary side rectifier circuit. The first secondary side rectifier circuit receives the first secondary side AC voltage and outputs a first temporal portion of the output DC voltage during a first portion of a duty cycle. The second secondary side rectifier circuit receives the second secondary side AC voltage and outputs a second temporal portion of the output DC voltage during a second portion of the duty cycle.

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: A DC-DC converter includes a first switching network that receives the input DC voltage and outputs a first AC voltage, a transformer, and a secondary side conversion circuit that receives the second AC voltage and outputs the output DC voltage. The transformer includes a first plurality of primary windings, a second plurality of primary windings and a plurality of secondary windings. The transformer is configured to receive the first AC voltage and outputting a second AC voltage. When the input DC voltage is intended to be used in a low voltage range, the first plurality of primary windings and the second plurality of primary windings are configured to be in parallel at the time the DC-DC converter is manufactured. When the input DC voltage is intended to be used in a high voltage range the first plurality of primary windings and the second plurality of primary windings are configured to be in series at the time of manufacture.

Abstract: A DC-DC converter includes a first switching network that receives an input DC voltage and outputs a first AC voltage, a transformer, and a secondary side conversion circuit. The first switching network receives an input DC voltage. The transformer includes a middle-point primary tap such that when the input DC voltage is in a low voltage range, the middle-point tap of the transformer primary is connected to the input DC voltage causing current to flow through the first plurality of primary windings in parallel to current flowing through the second plurality of primary windings and when the input DC voltage is in a high voltage range, the middle-point tap is disconnected from the input DC voltage causing current to flow through the first plurality of primary windings in series with current flowing through the second plurality of primary windings.

Abstract: In at least one embodiment, a vehicle battery charger is provided. The vehicle battery charger includes at least one transformer, a first modular converter, a filter, and at least one controller. The first modular converter includes a first plurality of switching devices to generate a first voltage signal in response to a filtered input signal. A second plurality of switching devices generate a second voltage signal. The filter is operably coupled to the first modular converter and provides the filtered input signal to the first modular converter in response to a first input signal from a mains supply. The filtered input signal includes a detectable current portion and an undetected current portion. The controller is programmed to determine the undetected current portion based at least on a capacitance of the filter and generate a first control variable to compensate for the undetected current portion.

Abstract: A bidirectional or unidirectional DC-DC converter includes a primary stage and a secondary stage. The primary stage is configured to receive or output a first DC voltage. The primary stage includes a first switching network configured to convert the first DC voltage to a first alternating current (AC) voltage or vice versa. The DC-DC converter also includes a transformer having primary windings and secondary windings. The primary windings are in electrical communication with the first switching network. The transformer is configured to convert between the first AC voltage and a second AC voltage. The DC-DC converter also includes a secondary stage that has a second switching network. Characteristically, the second switching network and the transformer operate as an interleaved converter to convert the second AC voltage to an output DC voltage or vice versa. Advantageously, the required series inductance for this interleaved converter is integrated into the transformer.

Abstract: In at least one embodiment, an apparatus including a pulse buffer (PB) converter. The PB converter including a housing, a printed circuit board (PCB), at least one inductor, and at least one capacitor is provided. The PCB is positioned in the housing and includes at least one first power switch and at least one second power switch positioned thereon. The at least one inductor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least second power switch. The at least one capacitor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least one second power switch to regulate an energy output to one or more vehicle batteries during a charging operation.

Abstract: In at least one embodiment, a vehicle battery charger is provided. At least one transformer includes a first winding and a second winding on a primary side of the transformer that are connected to one another to form a middle point. The middle point of the at least one transformer receives an input voltage signal from a mains supply. A half-bridge rectifier receives the input voltage signal from the mains supply to enable the middle point of the least one transformer to receive the input voltage signal from the mains supply. A first active bridge includes a first plurality of switching devices to receive a first input signal directly from the first winding and to receive a second input signal directly from the second winding. The first input signal and the second input signal are out of phase with one another to minimize electromagnetic interference within the vehicle battery charger.

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.