Battery charger for electric vehicles

• US 10,166,873 B2
• Filed: 07/18/2013
• Issued: 01/01/2019
• Est. Priority Date: 01/19/2011
• Status: Active Grant

• Current Assignee: ABB BV (ABB Limited)
• Original Assignee: ABB BV (ABB Limited)
• Inventors: Kardolus, Menno, Schijffelen, Jos, Groninger, Mark, Van Casteren, Dolf
• Primary Examiner(s): Henze-Gongola, David V
• Assistant Examiner(s): Rankine, Tarikh
• Application Number:
  US13/945,525
• Publication Number:
  US 20130314038A1
• Time in Patent Office: 1,993 Days
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 3/00 Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00
• 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: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H02J 1/108 using diodes blocking reverse current flow H02J1/12 takes precedence
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 1/0048 Circuits or arrangements for reducing losses using snubbers H02M1/34
• CPC Class Codes: H02M 7/23 arranged for operation in parallel H02M7/2176 takes precedence
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A battery charger for electric vehicles includes at least three identical current controlled AC-DC converter modules having reverse current protected outputs connected in parallel to a charge terminal of the battery.

Claims

1. A battery charger for electric vehicles, the battery charger comprising:

at least one converter unit composed of three converter modules and having a power supply circuit configured to be switched between a three-phase supply mode and a single-phase supply mode;

wherein the power supply circuit comprises three first bridge circuits by which, in the three-phase supply mode, input sides of the converter modules are connected phase-against-phase in a triangular configuration, and three second bridge circuits by which, in the single phase mode, the input sides of the converter modules are connected phase-against-ground in a star configuration;

wherein the converter modules comprise identical current controlled DC-DC converter modules having reverse current protected outputs connected in parallel to a charge terminal of a vehicle battery.

2. The battery charger according to claim 1, wherein the power supply circuit comprises a mode selector configured to detect the presence of voltages on mains conductors and to automatically select the supply mode in response to the detected voltages.

3. The battery charger according to claim 1, wherein the converter modules are configured as resonant converters.

4. The battery charger according to claim 3, comprising:

a controller configured to individually control output currents of the converter modules in accordance with a variable demand signal such that a current demand is met with the smallest possible number of active converter modules, with as many converter modules as possible operating at full power.

5. The battery charger according to claim 1, wherein the battery charger is configured as an on-board battery charger and comprises:

a controller; and

a circuit board on which electronic components are mounted and which is supported on a liquid cooled base plate connecting to a coolant system of a vehicle,

wherein the controller of the battery charger is adapted to control the liquid coolant system.

6. The battery charger according to claim 1, wherein the battery charger is configured as a stationary charger connectable to the vehicle battery via a power plug connector.

7. The battery charger according to claim 6, comprising:

a plurality of the converter units, wherein the outputs of the converter units are connected in parallel to the power plug connector.

8. The battery charger according to claim 7, wherein the three converter modules of each converter unit are respectively connectable phase-against-phase in a triangular configuration, and

wherein the battery charger comprises a control system having a mode of operation in which at least two converter units are configured to operate at reduced power simultaneously, with at least one converter module in each of these units being disabled.

9. The battery charger according to claim 1, comprising:

a monitoring circuit configured to detect a contact condition of a power plug connector; and

a controller configured to abort the battery charge process when the monitoring circuit detects a bad contact condition of the power plug connector.

10. The battery charger according to claim 1, comprising:

a controller connectable to a battery controller for the vehicle battery and configured to transmit an error signal to the battery controller for switching the battery controller to a reduced power charge mode when at least one of the converter modules fails.

11. A battery charging system for electric vehicles, comprising:

an on-board battery charger according to claim 5, wherein;

the battery charger is configured as a stationary charger connectable to the vehicle battery via a power plug connector; and

the on-board battery charger has the same design as a single module or a single unit of the stationary battery charger.

12. The battery charger according to claim 4, wherein:

each converter module has at least two different modes of operation which cover different ranges of output currents; and

the controller is configured to control the converter modules, in response to a change of the demand signal, such that a step-wise change of the output current caused by switching the mode of operation is compensated by changing a switching frequency of the resonant converter, so that the output current becomes a continuous function of the demand signal.

13. The battery charger according to claim 4, wherein the battery charger is configured as an on-board battery charger and comprises:

a circuit board on which electronic components are mounted and which is supported on a liquid cooled base plate connecting to a coolant system of a vehicle,

wherein the controller of the battery charger is adapted to control the liquid coolant system.

14. The battery charger according to claim 7, wherein the supply circuit of each converter unit comprises a mode selector configured to detect the presence of voltages on mains conductors and to automatically select a supply mode in response to the detected voltages.

15. The battery charger according to claim 6, comprising:

a plurality of the converter units wherein the three converter modules of each converter unit are respectively connectable phase-against-phase in a triangular configuration; and

a control system having a mode of operation in which at least two converter units are configured to operate at reduced power simultaneously, with at least one converter module in each of these units being disabled.

16. The battery charger according to claim 7, comprising:

a monitoring circuit configured to detect a contact condition of the power plug connector; and

a controller configured to abort the battery charge process when the monitoring circuit detects a bad contact condition of the plug connector.

17. The battery charger according to claim 8, comprising:

a monitoring circuit configured to detect a contact condition of the power plug connector; and

a controller configured to abort the battery charge process when the monitoring circuit detects a bad contact condition of the plug connector.

18. The battery charging system according to claim 11, comprising:

a plurality of the converter units,

wherein the outputs of the converter units are connected in parallel to a power plug connector.

19. The battery charging system according to claim 18, wherein the three converter modules of each converter unit are respectively connectable phase-against-phase in a triangular configuration, and

wherein the battery charger comprises a control system having a mode of operation in which at least two converter units are configured to operate at reduced power simultaneously, with at least one converter module in each of these units being disabled.

20. The battery charging system according to claim 18, comprising:

a monitoring circuit configured to detect a contact condition of the power plug connector; and

a controller configured to abort the battery charge process when the monitoring circuit detects a bad contact condition of the plug connector.

21. The battery charging system according to claim 18, comprising:

a controller connectable to a battery controller for the vehicle battery and configured to transmit an error signal to the battery controller for switching the battery controller to a reduced power charge mode when at least one of the converter modules fails.

22. A battery charger for electric vehicles, the battery charger comprising:

at least three identical current controlled AC-DC converter modules having reverse current protected outputs connected in parallel to a charge terminal of a vehicle battery;

wherein the converter modules are configured as resonant converters;

a controller configured to individually control output currents of the converter modules in accordance with a variable demand signal such that a current demand is met with the smallest possible number of active converter modules, with as many converter modules as possible operating at full power;

wherein each of the converter modules has at least two different modes of operation which cover different ranges of output currents;

wherein the converter modules comprise a power supply circuit configured to be switched between a three-phase supply mode and a single-phase supply mode;

wherein the power supply circuit comprises three first bridge circuits by which, in the three-phase supply mode, input sides of the converter modules are connected phase-against-phase in a triangular configuration, and three second bridge circuits by which, in the single phase mode, the input sides of the converter modules are connected phase-against-ground in a star configuration; and

the controller is configured to control the converter modules, in response to a change of the demand signal, such that a step-wise change of the output current caused by switching the mode of operation is compensated by changing a switching frequency of the resonant converter, so that the output current becomes a continuous function of the demand signal.