Apparatus and method for rapid charging using shared power electronics

• US 10,377,259 B2
• Filed: 09/19/2017
• Issued: 08/13/2019
• Est. Priority Date: 12/18/2009
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: King, Robert Dean, Steigerwald, Robert Louis
• Primary Examiner(s): Pacheco, Alexis B
• Application Number:
  US15/708,859
• Publication Number:
  US 20180001773A1
• Time in Patent Office: 693 Days
• Field of Search: 320107, 320108, 320109, 320104, 320128, 320111, 320138, 320134, 320132, 320135, 320137, 320145, 320152, 320162, 307 43, 307 44, 307 45, 307 46, 307 47, 307 48, 307 64, 307 65, 307 66, 307 67, 307 85, 307 87, 307 82, 307 80, 307 101, 180 651, 180 6521, 180 6529, 903903, 903907
• CPC Class Codes: B60L 2200/36 Vehicles designed to transport cargo, e.g. trucks
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/72 Charging station selection relying on external data
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• CPC Class Codes: B60L 7/12 for vehicles propelled by dc motors
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60L 9/22 polyphase motors
• CPC Class Codes: B60L 9/28 polyphase motors
• 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 7/0013 : acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0029 : with safety or protection devices or circuits
• CPC Class Codes: H02J 7/0045 : concerning the insertion or the connection of the batteries
• 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 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y04S 30/12 : Remote or cooperative charging
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor

Abstract

An apparatus comprises a power electronic energy conversion system comprising a first energy storage device configured to store DC energy and a first voltage converter configured to convert a second voltage from a remote power supply into a first charging voltage configured to charge the first energy storage device. The apparatus also includes a first controller configured to control the first voltage converter to convert the second voltage into the first charging voltage and to provide the first charging voltage to the first energy storage device during a charging mode of operation and communicate with a second controller located remotely from the power electronic energy conversion system to cause a second charging voltage to be provided to the first energy storage device during the charging mode of operation to rapidly charge the first energy storage device.

Claims

1. A vehicle charging system comprising:

an energy storage device;

a first DC/DC converter coupleable via a first switching device to the energy storage device;

power electronics comprising a second DC/DC converter for a traction drive system coupleable to the energy storage device via a second switching device, the traction drive system comprising an inverter coupled to a traction motor;

wherein the second switching device is configured to selectively decouple the second DC/DC converter from the energy storage device during a period when the energy storage device is coupled to the first DC/DC converter via the first switching device to be charged from an external charging source.

2. The vehicle charging system of claim 1, further comprising a controller configured to selectively open the second switching device to electrically decouple the second DC/DC converter from the energy storage device during a period when the first switching device is closed to electrically couple the first DC/DC converter to the energy storage device to charge the energy storage device from the external charging source.

3. The vehicle charging system of claim 1, further comprising a second energy storage device.

4. The vehicle charging system of claim 3, further comprising an auxiliary drive configured to receive a modified voltage from the second energy storage device.

5. The vehicle charging system of claim 3, wherein the second energy storage device is coupleable to the traction drive system via a third switching device.

6. The vehicle charging system of claim 1, further comprising an axle coupled to the traction motor, the axle including one or more drive wheels.

16. The vehicle charging system of claim 1, wherein the first DC/DC converter is configured to operate in a bucking mode.

17. The vehicle charging system of claim 1, wherein the second DC/DC converter is configured to operate in a boosting mode and a bucking mode.

18. The vehicle charging system of claim 1, wherein:

the first DC/DC converter is configured to operate in a bucking mode; and

the second DC/DC converter is configured to operate in a boosting mode and a bucking mode.

7. A vehicle charging system comprising:

a first energy storage device;

a second energy storage device;

a first DC/DC converter coupleable to the first energy storage device;

an auxiliary drive coupleable to the second energy storage device;

power electronics comprising a second DC/DC converter for a traction drive system comprising an inverter coupled to a traction motor; and

a plurality of switching devices configured to selectively couple the first energy storage device to the first DC/DC converter, couple the second energy storage device to the second DC/DC converter, and decouple the second DC/DC converter from the first energy storage device during a period when the first and second energy storage devices are being charged from an external charging source, the plurality of switching devices comprising;

a first switching device coupled between the first DC/DC converter and the first energy storage device;

a second switching device coupled between the second DC/DC converter and the second energy storage device; and

a third switching device coupled between the second DC/DC converter and the first energy storage device.

8. The vehicle charging system of claim 7, wherein the first energy storage device comprises a first battery and the second energy storage device comprises a second battery.

9. The vehicle charging system of claim 8, wherein the first battery has a lower voltage than the second battery.

10. The vehicle charging system of claim 7, wherein the auxiliary drive comprises an air-conditioning compressor.

11. The vehicle charging system of claim 7, wherein the external charging source comprises an AC source.

19. The vehicle charging system of claim 7, further comprising a controller configured to selectively open the third switching device to decouple the second DC/DC converter from the first energy storage device during a period when the first switching device and second switching device are closed to couple the first DC/DC converter to the first energy storage device and the second DC/DC converter to the second energy storage device, respectively, to charge the first and second energy storage devices from the external charging source.

12. A vehicle charging system comprising:

an energy storage device;

a first DC/DC converter coupleable to the energy storage device, the first DC/DC converter being configured to operate in a bucking mode;

power electronics comprising a second DC/DC converter for a traction drive system comprising an inverter coupled to a motor/generator, the second DC/DC converter being configured to operate in a boosting mode and a bucking mode;

a first switching device coupled between the first DC/DC converter and the energy storage device; and

a second switching device coupled between the second DC/DC converter and the energy storage device, the second switching device being configured to selectively decouple the second DC/DC converter from the energy storage device during a period when the first switching device couples the first DC/DC converter to the energy storage device to charge the energy storage device from an external charging source.

13. The vehicle charging system of claim 12, further comprising an axle coupled to the motor/generator, the axle including one or more drive wheels.

14. The vehicle charging system of claim 13, wherein the motor/generator operates as a generator during a regenerative braking mode.

15. The vehicle charging system of claim 14, wherein the motor/generator charges the energy storage device when operating as a generator.

20. The vehicle charging system of claim 12, further comprising a controller configured to selectively open the second switching device to decouple the second DC/DC converter from the energy storage device during a period when the first switching device is closed to couple the first DC/DC converter to the energy storage device to charge the energy storage device from the external charging source.