Systems and methods for supplying power in a hybrid vehicle using capacitors, a battery and one or more DC/DC converters

• US 10,124,793 B2
• Filed: 07/12/2016
• Issued: 11/13/2018
• Est. Priority Date: 03/02/2016
• Status: Active Grant

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Ciaccio, Michael Peter, Moorhead, Brian
• Primary Examiner(s): Gannon, Levi
• Application Number:
  US15/208,112
• Publication Number:
  US 20170253231A1
• Time in Patent Office: 854 Days
• Field of Search: 307 106
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/44 related to combustion engines
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60L 7/10 Dynamic electric regenerative braking B60L7/22 takes precedence
• CPC Class Codes: B60R 16/033 characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/15 Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 2510/244 Charge state
• CPC Class Codes: B60Y 2300/63 Starter motor mode
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: F02N 11/0866 comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 2011/0885 Capacitors, e.g. for additional power supply
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: F02N 2011/0896 Inverters for electric machines, e.g. starter-generators
• CPC Class Codes: F02N 2200/061 : Battery state of charge [SOC]
• CPC Class Codes: F02N 2200/062 : Battery current
• CPC Class Codes: F02N 2200/063 : Battery voltage
• CPC Class Codes: F02N 2200/064 : Battery temperature
• CPC Class Codes: H01M 10/44 : Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/615 : Heating or keeping warm
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/6572 : Peltier elements or thermoelectric devices
• CPC Class Codes: H01M 16/003 : of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H02J 2207/20 : Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 2310/48 : for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/1423 : with multiple batteries
• CPC Class Codes: H02J 7/345 : using capacitors as storage or buffering devices
• CPC Class Codes: H02M 3/04 : by static converters
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements

Abstract

A power management system for a hybrid vehicle including an engine includes a vehicle power bus distributing power from a battery to vehicle loads. A capacitor includes one of a plurality of supercapacitors and a plurality of ultracapacitors. A starter/generator controller communicates with the capacitor and the battery. A power management module is configured to supply current from the capacitor to the starter/generator controller during cranking of the engine; and supply current from the battery to the starter/generator controller during the cranking of the engine. The power supplied by the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the cranking of the engine.

Claims

1. A power management system for a hybrid vehicle including an engine, comprising:

a battery;

a vehicle power bus that distributes power from the battery to vehicle loads;

a capacitor, wherein the capacitor includes one of a plurality of supercapacitors and a plurality of ultracapacitors;

a starter/generator controller that communicates with the capacitor and the battery;

a power management module configured to;

supply power from the capacitor to the starter/generator controller during cranking of the engine; and

supply power from the battery to the starter/generator controller during the cranking of the engine,

wherein the power supplied by the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the cranking of the engine; and

a battery and capacitor assembly including;

a cooling plate assembly;

a heat spreader;

zoned thermoelectric devices; and

mounting brackets,

wherein the battery includes pouch-type battery cells and the capacitor includes pouch-type capacitor cells, and

wherein the pouch-type battery cells and the pouch-type capacitor cells are arranged between the mounting brackets and in thermal contact with the heat spreader and the zoned thermoelectric devices.

2. The power management system of claim 1, wherein the battery has a current/capacity ratio that is less than or equal to 6.

3. The power management system of claim 1, wherein a capacity of the battery is less than or equal to 20 Ah.

4. The power management system of claim 1, wherein current from the battery is controlled to less than or equal to 100 amps during cranking.

5. The power management system of claim 1, further comprising an overvoltage protection circuit connected to the battery.

6. The power management system of claim 1, further comprising:

a first current detector circuit connected in series with the battery; and

a second current detector circuit connected in series with the capacitor.

7. The power management system of claim 1, further comprising:

a DC/DC converter connected between the capacitor and the vehicle power bus,

wherein the DC/DC converter controls the current flowing from the battery to the starter/generator controller during cranking of the engine.

8. The power management system of claim 7, wherein the DC/DC converter includes:

a DC/DC boost converter connected between the capacitor and the vehicle power bus; and

a DC/DC buck converter connected between the capacitor and the vehicle power bus.

9. The power management system of claim 8, wherein, during cranking of the engine, the power management module disables the DC/DC buck converter and enables the DC/DC boost converter.

10. The power management system of claim 9, wherein the power management module controls the DC/DC boost converter to control current supplied by the battery to the starter/generator controller during the cranking.

11. The power management system of claim 1, further comprising an electric motor or starter/generator connected to the starter/generator controller, wherein the cranking of the engine is followed by an e-boost event, and wherein power is supplied to the electric motor or starter/generator during the e-boost event.

12. The power management system of claim 11, wherein the power management module is further configured to:

supply power from the capacitor to the starter/generator controller during the e-boost event; and

supply power from the battery to the starter/generator controller during the e-boost event,

wherein the power supplied by the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the e-boost event.

13. The power management system of claim 1, further comprising:

an AC/DC converter connected to the starter/generator controller; and

a starter/generator connected to the AC/DC converter and the engine.

14. The power management system of claim 13, wherein the power management module is further configured to:

recharge the capacitor using power generated by the starter/generator during a regeneration event; and

control flow of power from the starter/generator or the capacitor to the battery during the regeneration event,

wherein the power flowing from the starter/generator or the capacitor to the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the battery during the regeneration event.

15. The power management system of claim 1, wherein the power from the battery is greater than or equal to 5% and less than or equal to 15% of the total power supplied to the starter/generator controller during the cranking of the engine.

16. The power management system of claim 1, wherein the zoned thermoelectric devices maintain the battery within a first predetermined temperature range and the capacitor within a second predetermined temperature range.

17. The power management system of claim 16, wherein the first predetermined temperature range is different than the second predetermined temperature range.

18. A method for providing power in a hybrid vehicle including an engine, comprising:

distributing power from a battery to vehicle loads;

supplying power from a capacitor to a starter/generator controller during cranking of the engine,

wherein the capacitor includes one of a plurality of supercapacitors and a plurality of ultracapacitors;

supplying power from the battery to the starter/generator controller during the cranking of the engine,

wherein the power from the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the cranking of the engine;

arranging the battery and the capacitor in a battery and capacitor assembly including a cooling plate assembly, a heat spreader, zoned thermoelectric devices, and mounting brackets,

wherein the battery includes pouch-type battery cells and the capacitor includes pouch-type capacitor cells; and

arranging the pouch-type battery cells and the pouch-type capacitor cells between the mounting brackets and in thermal contact with the heat spreader and the zoned thermoelectric devices.

19. The method of claim 18, wherein the battery has a current/capacity ratio that is less than or equal to 6.

20. The method of claim 18, wherein a capacity of the battery is less than or equal to 20 Ah.

21. The method of claim 18, wherein current from the battery is controlled to less than or equal to 100 amps during the cranking.

22. The method of claim 18, further comprising:

detecting current supplied by the battery; and

detecting current supplied by the capacitor.

23. The method of claim 18, further comprising controlling the current flowing from the battery to the starter/generator controller during cranking of the engine.

24. The method of claim 23, further comprising:

connecting a DC/DC boost converter between the capacitor and a vehicle power bus; and

connecting a DC/DC buck converter between the capacitor and the vehicle power bus.

25. The method of claim 24, further comprising, during cranking of the engine, disabling the DC/DC buck converter and enabling the DC/DC boost converter.

26. The method of claim 25, further comprising controlling the DC/DC boost converter to control current flow supplied by the battery to the starter/generator controller during cranking.

27. The method of claim 18, further comprising:

connecting an electric motor or starter/generator to the starter/generator controller,

wherein the cranking of the engine is followed by an e-boost event; and

supplying power to the electric motor or starter/generator during the e-boost event.

28. The method of claim 27, further comprising:

supplying power from the capacitor to the starter/generator controller during the e-boost event; and

supplying power from the battery to the starter/generator controller during the e-boost event,

wherein the power from the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the e-boost event.

29. The method of claim 18, further comprising:

connecting an AC/DC converter to the starter/generator controller; and

connecting a starter/generator the AC/DC converter and the engine.

30. The method of claim 29, further comprising:

recharging the capacitor using power generated by the starter/generator during a regeneration event; and

controlling flow of power from the starter/generator to the battery during the regeneration event,

wherein the power flowing from the starter/generator or the capacitor to the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the battery during the regeneration event.

31. The method of claim 18, wherein the power from the battery is greater than or equal to 5% and less than or equal to 15% of the total power supplied to the starter/generator controller during the cranking of the engine.

32. The method of claim 18, further comprising maintaining the battery within a first predetermined temperature range and the capacitor within a second predetermined temperature range using the zoned thermoelectric devices.

33. The method of claim 32, wherein the first predetermined temperature range is different than the second predetermined temperature range.