Charge management system

• US 10,250,058 B2
• Filed: 09/15/2016
• Issued: 04/02/2019
• Est. Priority Date: 09/15/2016
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Lindsay, Bruce J.
• Primary Examiner(s): Kik, Phallaka
• Application Number:
  US15/266,531
• Publication Number:
  US 20180076646A1
• Time in Patent Office: 929 Days
• Field of Search: 320128, 320134, 320135, 320159, 320164
• CPC Class Codes: G05F 1/56 using semiconductor devices in series with the load as final control devices G05F1/461 takes precedence
• CPC Class Codes: H02H 9/00 Emergency protective circuit arrangements for limiting excess current or voltage without disconnection
• CPC Class Codes: H02H 9/002 limiting inrush current on switching on of inductive loads subjected to remanence, e.g. transformers
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02M 3/07 using capacitors charged and discharged alternately by semiconductor devices with control electrode , e.g. charge pumps

Abstract

A charge management system including a power distribution bus circuit for distributing energy from a power source to a load, and an intermediate energy storage circuit operably connected to a power distribution bus circuit for aiding in distribution of energy to the load. A charge management system controller may be configured to control the discharge of energy between the intermediate storage circuit and the power distribution bus circuit during one or more modes. Such a charge management system may enable the power distribution bus circuit to receive energy from the intermediate energy storage circuit before the power bus voltage drops in response to load demand, which may enable the power source to respond to perturbations in the power bus voltage and minimize inrush current from the power source. The system also may be used to soft-start high-power equipment, or absorb energy spikes associated with shut-down of such high-power equipment.

Claims

1. A method of operating a charge management system for distributing power from a power source to a load, the charge management system including a power distribution bus circuit operably connected to the power source and the load, and an intermediate energy storage circuit operably connected to the power distribution bus circuit, the method comprising:

(i) operably connecting the power source to the load;

(ii) charging at least one energy storage capacitor in the intermediate energy storage circuit;

(iii) determining load current demand at the load, and based upon a determination that the load demands current that meets or exceeds a predetermined level, activating a discharge switch to operably connect the at least one energy storage capacitor in the intermediate energy storage circuit to at least one power bus capacitor in the power distribution bus circuit, thereby discharging at least some energy stored in the at least one energy storage capacitor and at least some energy stored in the at least one power bus capacitor to the load;

(iv) deactivating the discharge switch to operably disconnect the at least one energy storage capacitor from the at least one power bus capacitor; and

(v) repeating steps (ii) through (iv).

2. The method according to claim 1, further comprising:

(i) charging at least one energy storage capacitor in the intermediate energy storage circuit;

(ii) activating a discharge switch to operably connect the at least one energy storage capacitor to at least one power bus capacitor in the power distribution bus circuit, thereby discharging at least some energy stored in the energy storage capacitor to the at least one power bus capacitor;

(iii) deactivating the discharge switch to operably disconnect the at least one energy storage capacitor from the at least one power bus capacitor; and

(iv) determining whether voltage across the at least one power bus capacitor is within a predetermined range;

wherein, when voltage across the at least one power bus capacitor is not within the predetermined range during the determining, then repeating steps (i) through (iv); and

wherein, when voltage across the at least one power bus capacitor is within the predetermined range during the determining, then operably connecting the power source to the load.

3. The method according to claim 2, wherein the deactivating the discharge switch is based upon a determination that the at least one energy storage capacitor and the at least one power bus capacitor are within a predetermined range.

4. The method according to claim 2, wherein the at least one energy storage capacitor is charged by activating an energy storage capacitor charge switch to operably connect the at least one energy storage capacitor to at least one energy source that is different from the power source;

wherein the charging the at least one energy storage capacitor includes charging to a predetermined level; and

after charging the at least one energy storage capacitor to the predetermined level, deactivating the energy storage capacitor charge switch to operably disconnect the at least one energy storage capacitor from the at least one energy source.

5. The method according to claim 1, wherein the deactivating the discharge switch is based upon a determination that the at least one energy storage capacitor and the at least one power bus capacitor are within a predetermined range.

6. The method according to claim 1, wherein the at least one energy storage capacitor is charged by activating an energy storage capacitor charge switch to operably connect the at least one energy storage capacitor to at least one energy source that is different than the power source.

7. The method according to claim 6, further comprising:

determining when a shutdown command signal has been received, and based upon a determination that the shutdown command signal has been received, deactivating the energy storage capacitor charge switch, and activating the discharge switch, thereby discharging the at least one energy storage capacitor and the at least one power bus capacitor.

8. The method according to claim 6,

wherein the at least one power bus capacitor is charged by activating at least one power relay switch to operably connect the at least one power bus capacitor to the power source;

wherein the at least one energy storage capacitor charge switch and the at least one power relay switch are independently operable to charge the respective at least one energy storage capacitor and the at least one power bus capacitor independently of each other; and

wherein, when the at least one energy storage capacitor and the at least one power bus capacitor are each fully charged, the voltage across the at least one energy storage capacitor is greater than the voltage across the at least one power bus capacitor for discharging a greater amount of energy from the at least one energy storage capacitor to the load than the amount of energy discharged from the at least one power storage capacitor to the load.

9. The method according to claim 8,

wherein the at least one energy source is operably coupled to the power source to receive energy from the power source.

10. The method according to claim 1,

wherein, during the charging the at least one energy storage capacitor, determining when the voltage across the at least one energy storage capacitor is within a predetermined range;

and

wherein the activating the discharge switch to operably connect the at least one energy storage capacitor to the at least one power bus capacitor is based upon a determination that the voltage across the at least one energy storage capacitor is within the predetermined range.

11. The method according to claim 1, wherein the at least one energy storage capacitor includes a first energy storage capacitor, a second energy storage capacitor, and a third energy storage capacitor, the second and third energy storage capacitors being operably connected in series with each other, and the first energy storage capacitor being operably connected in parallel with the second and third energy storage capacitors, such that when the discharge switch is activated, energy stored in the respective first, second, and third energy storage capacitors is instantaneously discharged to the load, thereby causing an increase in output voltage, current applied to the load, and current the being sourced by the primary power source.

12. The method according to claim 1, further comprising:

determining voltage across the at least one power bus capacitor in the power distribution bus circuit, and based upon a determination that the voltage across the at least one power bus capacitor is greater than a predetermined level, activating a capture charge switch to operably connect the at least one power bus capacitor to the at least one energy storage capacitor, thereby discharging at least some energy stored in the at least one power bus capacitor to the at least one energy capture capacitor, thereby causing a decrease in output voltage and current being sourced by the primary power source.

13. The method according to claim 12, further comprising:

deactivating the capture charge switch to operably disconnect the at least one power bus capacitor from the at least one energy storage capacitor, wherein the deactivating the capture charge switch is based upon a determination that the at least one energy storage capacitor and the at least one power bus capacitor are within a predetermined range.

14. The method according to claim 1, wherein the at least one energy storage capacitor includes a first energy storage capacitor and a second energy storage capacitor in series with each other, the respective first and second energy storage capacitors being configured to capture the energy discharged from the at least one power bus capacitor when the capture charge switch is activated.

15. The method according to claim 1, further comprising:

(i) determining voltage across at least one a power bus capacitor in the power distribution bus circuit, and based upon a determination that the voltage across the at least one power bus capacitor is greater than a predetermined level, activating a capture charge switch to operably connect the at least one power bus capacitor to at least one energy storage capacitor in the intermediate energy storage circuit, thereby discharging at least some energy stored in the at least one power bus capacitor to the at least one energy storage capacitor;

(ii) deactivating the capture charge switch to operably disconnect the at least one power bus capacitor from the at least one energy storage capacitor;

(iii) further charging the at least one energy storage capacitor in the intermediate energy storage circuit based upon a determination that the voltage across the at least one energy storage capacitor is below a predetermined level;

(iii) determining load current demand, and based upon a determination that the load demands current that meets or exceeds a predetermined level, activating a discharge switch to operably connect the at least one energy storage capacitor to the at least one power bus capacitor, thereby discharging at least some energy stored in the energy storage capacitor and at least some energy stored in the power bus capacitor to the load; and

(iv) deactivating the discharge switch to operably disconnect the at least one energy storage capacitor from the at least one power bus capacitor.

16. The method according to claim 15, wherein the at least one energy storage capacitor in the intermediate energy storage circuit includes a first energy storage capacitor, a second energy storage capacitor, and a third energy storage capacitor, the second and third energy storage capacitors being operably connected in series with each other, and the first energy storage capacitor being operably connected in parallel with the second and third energy storage capacitors;

wherein, when the capture charge switch is activated to operably connect the at least one power bus capacitor to the at least one energy storage capacitor, at least some energy stored in the at least one power bus capacitor is discharged to the second and third energy storage capacitors;

wherein, the further charging the at least one energy storage capacitor includes activating an energy storage capacitor charge switch to operably connect the first energy storage capacitor to at least one energy source that is different from the power source; and

wherein, when the discharge switch is activated, energy stored in the respective first, second, and third energy storage capacitors and energy stored in the at least one power bus capacitor is discharged to the load.

17. A charge management system for distributing power from a power source to a load via a power distribution bus circuit having at least one power bus capacitor, the charge management system comprising:

an intermediate energy storage circuit operably connected to the power distribution bus circuit, the intermediate energy storage circuit having at least one energy storage capacitor, and at least one discharge switch configured to operably connect or disconnect the at least one energy storage capacitor to or from the at least one power bus capacitor; and

a system controller operably connected to the power bus distribution circuit and the intermediate energy storage circuit;

wherein, in an operational mode, the system controller is configured to;

(i) operably connect the power source to the load;

(ii) determine whether the voltage across the at least one energy storage capacitor is at or above a predetermined level, and based upon a determination that the voltage across the energy storage capacitor is below the predetermined level, the controller is configured to activate the energy storage capacitor charge switch to operably connect the at least one energy storage capacitor to the at least one energy source, thereby enabling charging of the at least one energy storage capacitor;

(iii) determine load current demand at the load, and based upon a determination that the load demands current that meets or exceeds a predetermined level, activating the discharge switch to operably connect the at least one energy storage capacitor to the at least one power bus capacitor, thereby enabling discharging of at least some energy stored in the at least one energy storage capacitor and at least some energy stored in the at least one power bus capacitor to the load; and

(iv) deactivating the discharge switch to operably disconnect the at least one energy storage capacitor from the at least one power bus capacitor.

18. The charge management system according to claim 17, wherein, in a regenerative mode, the controller is configured to determine voltage across the at least one a power bus capacitor, and based upon a determination that the voltage across the at least one power bus capacitor is greater than a predetermined level, the controller is configured to activate a capture charge switch to operably connect the at least one power bus capacitor to the at least one energy storage capacitor, thereby enabling discharging of at least some energy stored in the at least one power bus capacitor to the at least one energy storage capacitor.

19. The charge management system according to claim 18, wherein the at least one energy storage capacitor includes a first energy storage capacitor, a second energy storage capacitor, and a third energy storage capacitor, the second and third energy storage capacitors being operably connected in series with each other across the intermediate energy storage circuit, and the first energy storage capacitor being operably connected in parallel with the second and third energy storage capacitors.

20. The charge management system according to claim 19,

wherein, in the operational mode, the controller is configured to activate the energy storage capacitor charge switch to operably connect the first energy storage capacitor to the at least one energy source, thereby enabling charging of the first energy storage capacitor;

and

wherein, in the regenerative mode, the controller is configured to activate the capture charge switch to operably connect the at least one power bus capacitor to the second and third capacitors, thereby enabling at least some energy stored in the at least one power bus capacitor to be discharged to the second and third energy storage capacitors;

wherein the controller is configured to activate the discharge switch, thereby enabling energy stored in the respective first, second, and third energy storage capacitors and energy stored in the at least one power bus capacitor to be discharged to the load.