Battery integrated isolated power converter and systems for electric vehicle propulsion

• US 10,351,253 B2
• Filed: 12/30/2015
• Issued: 07/16/2019
• Est. Priority Date: 12/30/2015
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Dong, Dong, Shah, Manoj Ramprasad, Zhou, Rui, Huang, Hao, Zhang, Di
• Primary Examiner(s): Fleming, Fritz M
• Application Number:
  US14/984,992
• Publication Number:
  US 20170190434A1
• Time in Patent Office: 1,294 Days
• CPC Class Codes: B60Y 2200/51 Aeroplanes
• CPC Class Codes: B60Y 2200/92 Hybrid vehicles
• CPC Class Codes: B64D 2221/00 Electric power distribution systems onboard aircraft
• CPC Class Codes: B64D 27/026 comprising different types of power plants, e.g. combination of a piston engine and a gas-turbine Hybrid electric aircraft B64D27/33
• CPC Class Codes: B64D 27/24 using steam or spring force jet aircraft B64D27/16
• CPC Class Codes: H02M 1/0077 Plural converter units whose outputs are connected in series
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/483 Converters with outputs that each can have more than two voltages levels
• CPC Class Codes: H02M 7/4835 comprising two or more cells, each including a switchable capacitor, the capacitors having a nominal charge voltage which corresponds to a given fraction of the input voltage, and the capacitors being selectively connected in series to determine the instantaneous output voltage
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters
• CPC Class Codes: H02M 7/797 using semiconductor devices only
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor

Abstract

An electric propulsion system includes at least one generator. The electric propulsion system also includes at least one drive engine coupled to the at least one generator. The electric propulsion system further includes at least one electrical device. The electric propulsion system also includes at least one battery integrated isolated power converter (BIIC), where the at least one generator and at least one of the at least one BIIC and the at least one electrical device are coupled, and where the at least one BIIC and the at least one electrical device are coupled.

Claims

1. A battery integrated isolated power converter (BIIC) comprising:

at least one BIIC module (BIICM) string comprising a plurality of BIICMs coupled to each other, each BIICM of the plurality of BIICMs comprising;

a first BIICM circuit comprising first, second, third, and fourth switching devices coupled together, the first switching device coupled to the second switching device, the third switching device coupled to the fourth switching device, both of the first switching device and the second switching device coupled in parallel across both of the third switching device and the fourth switching device;

a second BIICM circuit comprising a fifth switching device and a sixth switching device coupled to the fifth switching device;

a BIICM high-frequency transformer coupled to and between the first BIICM circuit and the second BIICM circuit, the BIICM high-frequency transformer including a first winding and a second winding, the first winding coupled in parallel across at least one of the third switching device or the fourth switching device, the second winding coupled in parallel across at least one of the fifth switching device or the sixth switching device, wherein the first BIICM circuit and the second BIICM circuit are physically isolated and inductively coupled through the BIICM high-frequency transformer;

one or more of;

(a) at least one energy storage device or (b) at least one capacitor coupled in parallel across at least one of;

both of the first switching device and the second switching device;

or

both of the fifth switching device and the sixth switching device.

2. The BIIC in accordance with claim 1, wherein the BIICM high-frequency transformer comprises first windings and at least a second winding, the BIICM high-frequency transformer including more of the first windings than the at least a second winding.

3. The BIIC in accordance with claim 1, wherein:

the at least one BIICM string further comprises at least three shunt strings, each of the shunt strings comprising at least a topmost BIICM and a bottommost BIICM;

wherein the first BIICM circuit further comprises;

a first node defined between the first switching device and the second switching device;

a second node defined between the first switching device and the third switching device; and

a third node defined between the second switching device and the fourth switching device; and

at least one of the BIICs further comprises;

at least three alternating current (AC) lines, each of the AC lines configured to transmit a phase of a 3-phase AC power to and from the at least one BIIC, wherein;

the first node of the topmost BIICM of each of the shunt strings coupled to one of the AC lines;

the third node of the bottommost BIICM of each of the shunt strings coupled together; and

the first nodes and the third nodes of the BIICMs other than the topmost BIICM and the bottommost BIICM of the shunt strings are serially coupled with each other.

4. The BIIC in accordance with claim 1, further comprising:

a bypass switch coupled in parallel across at least one of the first switching device or the second switching device; and

a bypass switch controller coupled to the bypass switch, the bypass switch controller configured to transmit a first control signal to the bypass switch to open the bypass switch responsive to at least one characteristic associated with at least one of the BIICMs having a first predetermined value, the bypass switch controller also configured to transmit a second control signal to the bypass switch to close the bypass switch responsive to the at least one characteristic having a second predetermined value that is different from the first predetermined value.

5. The BIIC in accordance with claim 1, wherein the first BIICM circuit further comprises:

a first node defined between the first switching device and the second switching device;

a second node defined between the first switching device and the third switching device;

a third node defined between the second switching device and the fourth switching device;

a direct current (DC) link; and

a first AC line configured to transmit a phase of a 3-phase AC power to and from the BIIC, wherein the at least one BIICM string further comprises;

a first half string comprising a first plurality of the BIICMs comprising at least a first topmost BIICM and a first bottommost BIICM;

a second half string comprising a second plurality of the BIICMs comprising at least a second topmost BIICM and a second bottommost BIICM; and

a power terminal coupled to and between the first half string and the second half string, the power terminal further coupled to the first AC line.

6. The BIIC in accordance with claim 5, further comprising a first inductor and a second inductor, wherein:

the first inductor is coupled to and between the power terminal and the third node of the first bottommost BIICM; and

the second inductor is coupled to and between the power terminal and the first node of the second topmost BIICM.

7. The BIIC in accordance with claim 5, further comprising at least three of the first AC line and at least three panels, each of the panels comprising one of the BIICM strings, wherein:

both of the third node of the first bottommost BIICM and the first node of the second topmost BIICM are coupled to the power terminal;

both of the first node of the first topmost BIICM and the third node of the second bottommost BIICM are coupled to the DC link;

the first nodes of the BIICMs of the first half string other than the first node of the first topmost BIICM are serially coupled to the third nodes of the BIICMs of the first half string other than the third node of the first bottommost BIICM; and

the first nodes of the BIICMs of the second half string other than the first node of the second topmost BIICM are serially coupled to the third nodes of the BIICMs of the second half string other than the third node of the second bottommost BIICM.

8. The BIIC in accordance with claim 1, wherein the second BIICM circuit further comprises a seventh switching device and an eighth switching device coupled to the seventh switching device, both of the seventh switching device and the eighth switching device coupled in parallel across both of the fifth switching device and the sixth switching device.

9. The BIIC in accordance with claim 8, further comprising:

a bypass switch coupled in parallel across at least one of the seventh switching device or the eighth switching device; and

a bypass switch controller coupled to the bypass switch, the bypass switch controller configured to transmit a control signal to the bypass switch to open the bypass switch responsive to at least one characteristic associated with at least one of the BIICMs having a first predetermined value and to close the bypass switch responsive to the at least one characteristic having a second predetermined value that is different from the first predetermined value.

10. The BIIC in accordance with claim 8, wherein:

the first BIICM circuit further comprises;

a first node defined between the first switching device and the second switching device;

a second node defined between the first switching device and the third switching device; and

a third node defined between the second switching device and the fourth switching device;

the second BIICM circuit further comprises;

a fourth node defined between the sixth switching device and the eighth switching device; and

a fifth node defined between the seventh switching device and the eighth switching device; and

the BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus; and

at least three first AC lines, wherein;

the at least one BIICM string further comprises at least three BIICM sets with each of the BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

the first nodes of the BIICM sets are coupled together and are further coupled to the first AC lines, each of the first AC lines configured to transmit a phase of a 3-phase AC power to and from the BIIC;

both of the fifth node of the topmost BIICM of the topmost BIICM set and the fourth node of the bottommost BIICM of the bottommost BIICM set are coupled to the DC link;

the second nodes of the BIICMs of the BIIC are coupled together through the first nodal bus;

the third nodes of the BIICMs of the BIIC are coupled together through the second nodal bus; and

the fourth nodes and the fifth nodes of the BIICMs other than the topmost BIICM of the topmost BIICM set and the bottommost BIICM of the bottommost BIICM set are serially coupled.

11. The BIIC in accordance with claim 8, wherein:

the first BIICM circuit further comprises;

a first node defined between the first switching device and the second switching device;

a second node defined between the first switching device and the third switching device; and

a third node defined between the second switching device and the fourth switching device;

the second BIICM circuit further comprises;

a fourth node defined between the sixth switching device and the eighth switching device; and

a fifth node defined between the seventh switching device and the eighth switching device;

the BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus; and

at least three AC lines; and

the at least one BIICM string further comprises at least three BIICM sets with each of the BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

the first nodes of of the BIICM sets are coupled together and further coupled to the AC lines, each of the AC lines configured to transmit a phase of a 3-phase AC power to and from the BIIC;

each of the fifth node of the topmost BIICM and the fourth node of the bottommost BIICM of each of the BIICM sets are coupled to the DC link;

the second nodes of the BIICMs of the BIIC are coupled together through the first nodal bus;

the third nodes of the BIICMs of the BIIC are coupled together through the second nodal bus; and

the fourth nodes and the fifth nodes of the BIICMs other than the topmost BIICM and the bottommost BIICM of each of the BIICM sets are serially coupled together.

12. The BIIC in accordance with claim 8, wherein the second BIICM circuit further comprises a ninth switching device and a tenth switching device coupled to the tenth switching device, both of the ninth switching device and the tenth switching device coupled in parallel across both of the seventh switching device and the eighth switching device.

13. The BIIC in accordance with claim 12, wherein:

the first BIICM circuit further comprises;

a first node defined between the first switching device and the second switching device;

a second node defined between the first switching device and the third switching device; and

a third node defined between the second switching device and the fourth switching device;

the second BIICM circuit further comprises;

a fifth node defined between the seventh switching device and the eighth switching device; and

a sixth node defined between the ninth switching device and the tenth switching device;

the BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus;

at least three first AC lines; and

at least three second AC lines;

wherein;

the at least one BIICM string further comprises at least three BIICM sets comprising a topmost BIICM set and a bottommost BIICM set, each of the BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

the first node of each of the topmost BIICM and the bottommost BIICM of each of the BIICM sets are coupled together and further coupled to one of the first AC lines, each of the first AC lines configured to transmit a phase of a 3-phase AC power to and from the BIIC;

the fifth node of the topmost BIICM of said of the BIICM sets is coupled to one of the second AC lines, each of the second AC lines configured to transmit a phase of a 3-phase AC power to and from the BIIC;

the second nodes of the BIICMs are coupled together through the first nodal bus;

the third nodes of the BIICMs are coupled together through the second nodal bus;

the fifth nodes and the sixth nodes and the fifth nodes of the BIICMs other than the topmost BIICM and the bottommost BIICM of each of the BIICM sets are serially coupled; and

the sixth nodes of all the bottommost BIICMs of each of the BIICM sets are coupled together.