Modular Medium Voltage AC to Low Voltage DC Converter for Extreme Fast Charging Applications

A modular and scalable converter for medium voltage (MV) AC to low voltage (LV) DC power conversion is proposed; single-phase-modules (SPMs), each consisting of an active-front-end (AFE) stage and an isolated DC-DC stage, are connected in input-series-output-parallel (ISOP) configuration to reach desired voltage and power capacity. In prior art, high-speed bidirectional communication among modules and a centralized controller is required to ensure module-level voltage and power balancing, which severely limits the scalability and practical realization of higher voltage and higher power systems. Moreover, large capacitors are used to suppress double-line-frequency voltage variations on the common MV DC bus shared by the AFE and the DC-DC stage originating from AC power pulsations through the SPMs. We propose a comprehensive controller which achieves voltage and power balancing using complete decentralized control of the DC-DC stages based on only local sensor feedback and the AFE stages are controlled using feedback of only the LV DC output. Furthermore, reduced capacitor requirement on the MV DC bus is achieved through design and control. The proposed method is validated through simulation and experimental results.