Generating leakage canceling current in electric vehicle charging systems

• US 10,139,848 B1
• Filed: 06/01/2017
• Issued: 11/27/2018
• Est. Priority Date: 08/27/2014
• Status: Active Grant

• Current Assignee: Motiv Power Systems, Inc.
• Original Assignee: Motiv Power Systems, Inc.
• Inventors: Treichler, William, Castelaz, James Michael, Zulauf, Grayson
• Primary Examiner(s): Williams, Arun
• Application Number:
  US15/611,734
• Time in Patent Office: 544 Days
• Field of Search: 320107
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: G05F 3/02 Regulating voltage or current
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A system includes a power source, a power converter, a leakage current cancelation circuit, a load, and a ground node. The power converter is coupled to the power source and supplies the load. During operation of the power converter, a common mode current flows from the load to the ground node via a leakage capacitance. The leakage current cancelation circuit receives at least one signal indicative of the common mode current and generates a leakage cancelation current that is injected into at least one node of the system. The leakage cancelation current has a magnitude opposite a magnitude of the common mode current. For example, the leakage current cancelation circuit receives supply voltage signals output by the power converter, and generates and supplies the leakage cancelation current onto input nodes of the power converter such that a current level on the ground node is between −3.0 milliamperes and +3.0 milliamperes.

Claims

1. A non-isolated charger module, comprising:

a power converter having a plurality of input leads, a first output lead, and a second output lead, wherein the power converter is adapted to receive an Alternating Current (AC) supply onto the plurality of input leads and to generate a positive Direct Current (DC) supply signal and a negative DC supply signal, and wherein the positive DC supply signal is supplied onto the first output lead and the negative DC supply signal is supplied onto the second output lead; and

a leakage current cancelation circuit having a first input lead and a second input lead, wherein the first input lead is coupled to the first output lead of the power converter, wherein the second input lead is coupled to the second output lead of the power converter, wherein the leakage current cancelation circuit generates a leakage cancelation current, and wherein the leakage cancelation current is supplied onto the plurality of input leads of the power converter.

2. The non-isolated charger module of claim 1, wherein the positive DC supply signal and the negative DC supply signal that are generated by the power converter are supplied to circuitry within the electric vehicle.

3. The non-isolated charger module of claim 1, wherein a current level on a ground node is below a predetermined current level of an electric vehicle charging station during operation of the non-isolated charger module.

4. The non-isolated charger module of claim 1, wherein the leakage cancelation current has a magnitude opposite a magnitude of a common mode current.

5. The non-isolated charger module of claim 1, further comprising:

a first AC input terminal that is coupled to a first of the plurality of input leads of the power converter;

a second AC input terminal that is coupled to a second of the plurality of input leads of the power converter;

a third AC input terminal that is coupled to a second of the plurality of input leads of the power converter;

a ground terminal coupled to the ground node of the electronic device;

a positive DC terminal that is coupled to the first output lead of the power converter; and

a negative DC terminal that is coupled to the second output lead of the power converter.

6. The non-isolated charger module of claim 1, wherein leakage current cancelation circuit comprises:

a current reference generator circuit having a positive DC input lead, a negative DC input lead, and a current reference voltage output lead, wherein the positive DC input lead is coupled to the first output lead of the power converter, and wherein the negative DC input lead is coupled to the second output lead of the power converter; and

a current controlled feedback circuit having an input lead and a leakage cancelation current output lead, wherein the input lead is coupled to the current reference voltage output lead of the current reference generator circuit.

7. The non-isolated charger module of claim 6, wherein the current reference generator circuit comprises:

a summing amplifier circuit having a first input node, a second input node, and an output node, wherein the summing amplifier circuit is coupled to receive a first voltage signal on the first input node, wherein the summing amplifier circuit is coupled to receive a second voltage signal on the second input node, wherein the first voltage signal is indicative of a voltage present on the first output lead of the power converter, wherein the second voltage signal is indicative of a voltage present on the second output lead of the power converter, and wherein the summing amplifier circuit generates and outputs a third voltage signal onto the output node;

a differentiator circuit having an input node, an output node, a capacitor, and a resistor, wherein the differentiator circuit is coupled to receive the third voltage signal generated by the summing amplifier circuit onto a first lead of the capacitor, wherein the first lead of the capacitor is coupled to the input node, wherein a second lead of the capacitor is coupled to a first lead of the resistor, wherein the first lead of the resistor is coupled to the output node, wherein a second lead of the resistor is coupled to the ground node of the electronic device, and wherein the differentiator circuit generates a fourth voltage signal supplied onto the output node; and

a voltage gain circuit having an input node and an output node, wherein the input node is coupled to receive the fourth voltage signal and generate a current reference voltage signal, wherein the current reference voltage signal is supplied onto the output node, and wherein the output node is coupled to the input lead of the current controlled feedback circuit.

8. The non-isolated charger module of claim 6, wherein the current controlled feedback circuit comprises:

a resistor;

an output current sense circuit having a first input node, a second input node, and an output node, wherein the first input node is coupled to a first lead of the resistor, and wherein the second input node is coupled to a second lead of the resistor; and

a reference current error amplifier having a first input node, a second input node, and an output node, wherein the first input node is coupled to the output node of the output current sense circuit, wherein the second output node is coupled to the current reference voltage output lead of the current reference generator circuit, wherein the reference current error amplifier is configured to generate and supply a leakage cancelation current onto the output node, and wherein the output node is coupled to the second lead of the resistor.

9. The non-isolated charger module of claim 1, wherein the leakage current cancelation circuit further comprises:

a charge injection circuit having an input lead, a first output lead, a second output lead, and a third output lead, wherein the input lead is coupled to the leakage cancelation current output lead of the current controlled feedback circuit, wherein the first output lead is coupled to a first input lead of the plurality of input leads of the power converter, wherein the second output lead is coupled to a second input lead of the plurality of input leads of the power converter, and wherein the third output lead is coupled to a third input lead of the plurality of input leads of the power converter.

10. The non-isolated charger module of claim 1, wherein no inductor is involved in generating the leakage cancelation current, and wherein no transformer is involved in generating the leakage cancelation current.

11. The non-isolated charger module of claim 1, wherein the non-isolated charger module is disposed within an electric vehicle, and wherein the non-isolated charger module is coupled to receive an AC supply from an electric vehicle charging station.

12. The non-isolated charger module of claim 11, wherein the non-isolated charger module does not include any inductor, wherein the non-isolated charger module does not include any transformer, wherein the non-isolated charger module does not include any discrete magnetic component, wherein no inductor is coupled between the non-isolated charger module and the electric vehicle charging station, wherein no transformer is coupled between the non-isolated charger module and the electric vehicle charging station, wherein no discrete magnetic component is coupled between the non-isolated charger module and the electric vehicle charging station, wherein no inductor is coupled between the non-isolated charger module and circuitry of the electric vehicle, wherein no transformer is coupled between the non-isolated charger module and circuitry of the electric vehicle, and wherein no discrete magnetic component is coupled between the non-isolated charger module and circuitry of the electric vehicle.

13. A method comprising:

(a) receiving a first voltage signal onto a first input node of a leakage current cancelation circuit and receive a second voltage signal onto a second input node of the leakage current cancelation circuit, wherein the first voltage signal is received from a first output node of a power converter of an electric vehicle, and wherein the second voltage signal is received from a second output node of the power converter;

(b) generating a current reference voltage signal from the received first and second voltage signals, wherein the current reference voltage signal is generated by summing and amplifying the received first and second voltage signals; and

(c) generating a cancelation current using the generated current reference voltage signal and supplying the cancelation current onto input nodes of the power converter, wherein the cancelation current is generated such that a current level at a ground node of the electric vehicle is below a predetermined current level, and wherein the generating of (b) and the generating of (c) do not involve any inductor or transformer components.

14. The method of claim 13, wherein the predetermined current level is a threshold current level of a Ground Fault Interrupter (GFI) circuit, and wherein the GFI circuit is part of an electric vehicle charging station that is coupled to charge the electric vehicle.

15. The method of claim 13, wherein the generating of (b) involves:

(b1) amplifying the first voltage signal to generate a first amplified voltage signal and amplifying the second voltage signal to generate a second amplified voltage signal;

(b2) receiving the first amplified voltage signal and the second amplified voltage signal onto a summing and amplifier circuit that generates and outputs an amplified Common Mode Voltage (CMV) signal;

(b3) receiving the amplified CMV signal onto a differentiator circuit, wherein the differentiator circuit generates and outputs a derivative amplified CMV signal; and

(b4) receiving the derivative amplified CMV signal onto a voltage gain circuit, wherein the voltage gain circuit generates the current reference voltage signal from the derivative amplified CMV signal.

16. The method of claim 13, wherein the generating of (c) involves:

(c1) receiving the current reference voltage signal and an output current sense voltage signal onto a reference current error amplifier, wherein the reference current error amplifier generates the cancelation current from the received current reference voltage signal and the output current sense voltage signal; and

(c2) sensing a voltage of the cancelation current across a resistor, wherein the output current sense voltage signal of (c1) is generated using the sensed voltage.

17. An electric vehicle charger module, comprising:

a power converter adapted to receive an Alternating Current (AC) supply and generate a positive Direct Current (DC) supply signal and a negative DC supply signal; and

means for generating a leakage cancelation current from the positive DC supply signal and the negative DC supply signal that are generated by the power converter, wherein the means is also for supplying the leakage cancelation current to the power converter such that a current level on a ground node of the electric vehicle charger module is maintained below a predetermined current level.

18. The electric vehicle charger module of claim 17, wherein the means comprises a current reference generator circuit, a current controlled feedback circuit, and a charge injection circuit.

19. The electric vehicle charger module of claim 17, wherein the predetermined current level is a threshold current level of a Ground Fault Interrupter (GFI) circuit, wherein the GFI circuit is part of an electric vehicle charging station that is coupled to charge an electric vehicle, wherein the electric vehicle charger module is disposed within the electric vehicle, and wherein the positive DC supply signal and the negative DC supply signal that are generated by the power converter are supplied to circuitry within the electric vehicle.

20. The electric vehicle charger module of claim 17, wherein no inductor, transformer, or discrete magnetic device is involved in generating the leakage cancelation current.