Onboard battery charging system

• US 10,411,488 B2
• Filed: 05/02/2016
• Issued: 09/10/2019
• Est. Priority Date: 05/02/2016
• Status: Expired due to Fees

• Current Assignee: Club Car Incorporated
• Original Assignee: Club Car Incorporated
• Inventors: King, Russell William
• Primary Examiner(s): Isla, Richard
• Assistant Examiner(s): Bui, Dung V
• Application Number:
  US15/144,078
• Publication Number:
  US 20170317513A1
• Time in Patent Office: 1,226 Days
• Field of Search: 320109
• 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 3/0092 with use of redundant elements for safety purposes
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/62 in response to charging parameters, e.g. current, voltage or electrical charge
• CPC Class Codes: H02J 2207/40 adapted for charging from various sources, e.g. AC, DC or multivoltage
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• 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
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

Unique systems, methods, techniques and apparatuses of onboard battery charger systems are disclosed. One exemplary embodiment is a battery charging system comprising an isolation device and an electric vehicle charger. The isolation device includes an AC input terminal; an AC output terminal; two DC output terminals; a first portion of a detection circuit including a first sensor and a first resistor coupled in series; and a first controller. The charger includes an AC input terminal; two DC input terminals; and a second portion of the detection circuit including a second sensor and a second resistor coupled in series. The first controller is structured to isolate the AC input terminal of the isolation device from the AC output terminal of the isolation device when the two DC input terminals of the electric vehicle charger are not coupled to the two DC output terminals of the isolation device.

Claims

1. A battery charging system comprising:

an isolation device comprising;

an AC input terminal structured to receive AC power;

an AC output terminal structured to provide AC power received with the AC input terminal;

two DC output terminals structured to transmit DC power;

a first portion of a detection circuit including a first sensor and a first resistor coupled in series, the first resistor being coupled in parallel to the two DC output terminals; and

a first controller in communication with the first sensor and structured to selectively isolate the AC input terminal of the isolation device from the AC output terminal of the isolation device; and

an electric vehicle charger comprising;

an AC input terminal structured to be coupled to the AC output terminal of the isolation device;

two DC input terminals structured to be coupled to the two DC output terminals of the isolation device; and

a second portion of the detection circuit including a second sensor and a second resistor coupled in series, the second resistor being coupled in parallel to the two DC input terminals,

wherein the first controller is structured to isolate the AC input terminal of the isolation device from the AC output terminal of the isolation device when the two DC input terminals of the electric vehicle charger are not coupled to the two DC output terminals of the isolation device.

2. The system of claim 1 wherein the first portion of the detector circuit includes a DC power source having a rectifier coupled to the AC input terminal and structured to receive AC power from the AC input terminal, convert the AC power to DC, and provide the DC power to the first portion of the detection circuit.

3. The system of claim 2 wherein the first sensor is structured to measure current flowing from the DC power source to the first resistor.

4. The system of claim 3 wherein the first controller is structured to receive the current measurement from the first sensor, compare the current measurement to a first range of current magnitudes, and allow AC power to flow from the AC input terminal to the AC output terminal in response to the received current measurement being within the first range of current magnitudes.

5. The system of claim 4 wherein the first controller is structured to isolate the AC input terminal from the AC output terminal in response to the received current measurement being within a second range of current magnitudes.

6. The system of claim 5 wherein the values of the first range of current magnitudes are less than the values of the second range of the current magnitudes.

7. The system of claim 1 wherein the isolation device comprises a relay coupled between the AC input terminal and the AC output terminal and coupled to the first controller, the relay being structured receive power from the first controller, transmit power from the AC input terminal to the AC output terminal in response to receiving power from the first controller, and disrupt the flow of power from the AC input terminal to the AC output terminal in response to not receiving power from the first controller.

8. The system of claim 1 wherein the second portion of the detection circuit comprises a switching device coupled in series with the second resistor and coupled in parallel with the two DC input terminals, the switching device also being coupled to a second controller and structured to open and close the switching device in response to receiving an activation signal from the second controller.

9. The system of claim 8 wherein the second controller is structured to open the switching device in response to receiving a current measurement from the second sensor.

10. The system of claim 1 wherein the second portion of the detection circuit includes a second DC power source structured such that the voltage across the first DC power source is greater than the voltage across the second DC power source.

11. The system of claim 1 wherein the AC input terminals of the isolation device and the electric vehicle charger include a hot connection point, a neutral connection point, and a ground connection point.

12. A battery charging system comprising:

an isolation device structured to receive AC power and selectively provide AC power;

an electric vehicle battery charger coupled to a battery, the battery charger structured to be coupled to the isolation device and receive AC power from the isolation device; and

a detection circuit including a first portion having a first DC current sensor and a second portion having a second DC current sensor, the first portion and second portion being structured to be coupled together when the battery charger is coupled to the isolation device,

wherein the first portion of the detection circuit is located within the isolation device and the second portion of the detection circuit is located within an electric vehicle,

wherein the detection circuit is structured such that the second DC current sensor measures a first current value when the isolation device is not receiving AC power but the isolation device is coupled to the battery charger, and

wherein the detection circuit is structured such that the second DC current sensor measures a second current value when the isolation device is receiving AC power and the isolation device is coupled to the battery charger.

13. The system of claim 12, wherein the first portion and second portion each additionally include a DC power source, a semiconductor device, and a second resistor coupled in series with the first or second DC current sensor, the first and second portion being structured to be coupled together by coupling the resistors of each portion in parallel.

14. The system of claim 12 wherein the battery is housed in a golf cart.

15. The system of claim 12 wherein the detection circuit is structured such that the first DC current sensor measures a first current value when the isolation device is receiving AC power but is not coupled to the battery charger;

the detection circuit is structured such that the first DC current sensor measures a second current value when the isolation device is receiving AC power and coupled to the battery charger; and

the detection circuit is structured such that the second DC current sensor measures a third current value when the isolation device is not coupled to the battery charger.

16. The system of claim 12 wherein the isolation device includes a cable having a plug and the electric vehicle battery charger includes a plug receptacle structured to be coupled to the plug of the isolation device.

17. The system of claim 16 wherein a portion of the detection circuit is housed in the cable of the isolation device.

18. A method for charging the battery of an electric vehicle comprising:

operating an isolation device including an AC input terminal;

an AC output terminal;

a DC output terminal;

a first detection circuit including a first DC power source, a first current sensor, a first diode, and a first resistor coupled in series; and

a first controller structured to selectively couple the AC input terminal and the AC output terminal;

operating an onboard battery charger including an AC input terminal;

a second detection circuit including a DC second power source, a second current sensor, a second diode, and a second resistor coupled in series; and

a second controller structured to control the first controller so as to selectively isolate the AC input terminal and the AC output terminal of the isolation device;

operating the first detection circuit so as to measure the current flowing from the DC first power source to the first diode and transmitting the current measurement to the first controller;

determining with the first controller whether the isolation device is coupled to an electric vehicle charger using the current measurement from the first current sensor; and

providing AC power to the electric vehicle charger in response to determining the isolation device is coupled to an electric vehicle charger.

19. The method of claim 18 additionally comprising:

measuring the magnitude of the current flowing from the second DC power source to the second diode with the second current sensor;

in response to determining the measured current is within a first range of current magnitude values, operating the second controller so as to disable the operational controls of the electric vehicle; and

in response to determining the measured current is within a second range of current magnitude values, operating the second controller so as to inactivate the onboard battery charger until the onboard battery charger receives AC power at the AC input terminal of the onboard battery charger.

20. The method of claim 18 additionally comprising:

detecting a fault within the isolation device with the first controller; and

storing fault data in memory.