Apparatus and method for an electric power supply with changeable electric connectivity between battery modules

• US 10,442,309 B2
• Filed: 04/27/2016
• Issued: 10/15/2019
• Est. Priority Date: 04/30/2015
• Status: Active Grant

• Current Assignee: Dr Ing hc F Porsche AG (Volkswagen AG)
• Original Assignee: Dr Ing hc F Porsche AG (Volkswagen AG)
• Inventors: Goetz, Stefan
• Primary Examiner(s): Tso, Edward
• Application Number:
  US15/551,820
• Publication Number:
  US 20180043789A1
• Time in Patent Office: 1,266 Days
• Field of Search: 320107, 320116, 320132, 320134, 320135, 320141, 320149, 320118, 320119
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/0019 using switched or multiplexed charge circuits
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/00304 Overcurrent protection
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• CPC Class Codes: H02J 7/1423 with multiple batteries
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• CPC Class Codes: H02M 3/33573 Full-bridge at primary side of an isolation transformer
• 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: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles

Abstract

A traction power source for electric vehicles in a single unit. Specifically, traction power source integrates several functions, such as the battery and inverter. In addition, further functionalities that are traditionally in separate units can be integrated into the system and efficiently performed by the same electronics, such as battery management and thermal management.

Claims

1. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches; and

at least one auxiliary power supply bus, wherein the at least one auxiliary power supply bus comprises at least two electric terminals that are pairwise electrically connected to at least two noncongruent electrical contacts of at least one battery subportion of at least one battery module.

2. The electrical circuit of claim 1, wherein said at least two alternatives of the electric connectivity include at least two of the following:

the at least one battery subportion of one battery module is electrically conductively connected in series with the at least one battery subportion of another battery module;

the at least one battery subportion of one battery module is electrically conductively connected in parallel with the at least one battery subportion of another battery module; and

the at least one battery subportion of one battery module is bypassed so that not more than one of the at least two noncongruent electrical contacts of the at least one battery subportion of said battery module is electrically conductively connected to the at least one battery subportion of another module.

3. The electrical circuit of claim 1, wherein said at least two alternatives of the electric connectivity comprise at least the following:

the at least one battery subportion of one battery module is electrically conductively connected in series with the at least one battery subportion of another battery module; and

the at least one battery subportion of one battery module is bypassed so that not more than one of the at least two noncongruent electrical contacts of the at least one battery subportion of said battery module is electrically conductively connected to the at least one battery subportion of another module.

4. The electrical circuit of claim 3, wherein said at least two alternatives of the electric connectivity further comprise the following:

the at least one battery subportion of one battery module is electrically conductively connected in parallel with the at least one battery subportion of another battery module.

5. The electrical circuit of claim 1, wherein the at least one battery subportion of one battery module is configured to be electrically conductively connected in series with the at least one battery subportion of another battery module with positive electrical polarity and with negative electrical polarity.

6. The electrical circuit of claim 1, wherein said at least one battery subportion in each of said at least three battery modules is an electrochemical energy storage cell with an energy content of at least 3 Wh.

7. The electrical circuit of claim 1, wherein at least one of the said electrical energy storages is a double-layer capacitor, in which energy is stored in Helmholtz charge double layers.

8. The electrical circuit of claim 1, wherein at least two battery subportions comprise different storage types such that they differ in at least two of the following characteristics by at least 50%:

energy capacity;

energy capacity per mass density;

peak power per mass density;

durability;

operating voltage range;

maximum specified current rise time;

specified peak current; and

cost.

9. The electrical circuit of claim 1, further comprising at least one electric machine.

10. The electrical circuit of claim 9, wherein said at least one electric machine is an alternating current machine with at least three electric phases.

11. The electrical circuit of claim 9, wherein said electric machine is operated at a voltage of at least four times a module voltage formed by the electrical energy storage elements of the respective module with the highest module voltage.

12. The electrical circuit of claim 1, wherein the at least one auxiliary power supply bus uses a rated voltage that does not deviate from a multiple of 12 V by more than 25%.

13. The electrical circuit of claim 1, wherein the at least one auxiliary power supply bus comprises at least one separate electrical energy storage which is operated at the voltage of the at least one auxiliary power supply bus.

14. The electrical circuit of claim 1, wherein the at least one auxiliary power supply bus further comprises at least two terminals each of which is electrically connected to at least one of said electric inter-battery-module connection lines.

15. The electrical circuit of claim 1, wherein a temporal average voltage of the at least one auxiliary power supply bus is lower than a maximum voltage the battery modules can generate between the at least two electric inter-module connection sites to which the at least two terminals of the at least one auxiliary power supply bus are electrically connected.

16. The electrical circuit of claim 15, wherein the temporal average voltage of at least one auxiliary power supply bus is lower than a third of the sum of the battery subportions of the battery modules.

18. The electrical circuit of claim 1, wherein the at least one auxiliary power supply bus further comprises at least one transformer.

19. The electrical circuit of claim 18, wherein the electrical circuit comprises at least one rectifier.

20. The electrical circuit of claim 1, further comprising at least two auxiliary power supply busses.

21. The electrical circuit of claim 20, wherein the at least two auxiliary power supply busses differ in voltage by at least 25%.

25. The electrical circuit of claim 1, wherein at least two modules further comprise at least one charge equilibration unit.

26. The electrical circuit of claim 25, wherein said at least one charge equilibration unit comprises at least one electric switch that is configured to be activated such that the charge level of a first part of a battery subportion is changed to a different extent than the charge level of a second part of the battery subportion.

27. The electrical circuit of claim 25, wherein said at least one charge equilibration unit comprises at least one voltage sensor.

28. The electrical circuit of claim 25, wherein said charge equilibration unit further comprises at least one electric switch that is connected electrically in series to at least one electrical energy storage element of the corresponding module.

29. The electrical circuit of claim 25, wherein said at least one charge equilibration unit further comprises at least one current sensor.

30. The electrical circuit of claim 1, wherein each of at least two battery modules further comprises at least one voltage sensor that monitors the voltage of at least one battery subportion of each respective battery subportion.

31. The electrical circuit of claim 1, wherein each of at least two battery modules further comprises at least two voltage sensors each of which detects the voltage of a different subsection of the same battery subportion, wherein said at least two different subsections are electrically connected in series to each other.

32. The electrical circuit of claim 1, wherein each of at least two battery modules further comprises at least one temperature sensor.

34. The electrical circuit of claim 1, wherein each of at least two battery modules further comprises at least one current sensor that detects the current flowing through at least one battery subportion.

35. The electrical circuit of claim 1, comprising at least one electronic controller that controls said at least two electric switches.

36. The electrical circuit of claim 1, wherein each of at least two battery modules comprises at least one electronic controller that effectively controls said at least two electric switches.

17. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches; and

at least one auxiliary power supply bus, wherein;

at least one auxiliary power supply bus further comprises at least two terminals each of which is electrically connected to at least one of said electric inter-battery-module connection lines, and

the at least one auxiliary power supply bus is configured to be temporarily disconnected from at least one of its terminals by at least one electric switch.

22. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches; and

at least two auxiliary power supply busses, wherein;

the at least two auxiliary power supply busses differ in voltage by at least 25%, and

at least one auxiliary power supply bus provides electric power for safety-relevant auxiliaries.

23. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches;

at least two auxiliary power supply busses; and

at least two auxiliary units configured to provide at least one same functionality electrically connected to different auxiliary power supply busses.

24. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches; and

at least two auxiliary power supply busses, wherein a functionality with specified safety level of at least ASIL C is provided by at least two auxiliaries that are electrically connected to different auxiliary power supply busses.

33. An electrical circuit comprising:

at least three battery modules, wherein;

each of said battery modules comprises at least one battery subportion and at least two electric switches,

each of said battery modules is electrically connected to at least a second of said battery modules through at least one electric inter-battery-module connection line, and

said at least two electric switches in each battery module are configured to change an electric connectivity between a first battery subportion of one of said battery modules and at least one second battery subportion of another of said battery modules between at least two alternatives of the electric connectivity by effective switching of said electric switches; and

at least one acceleration sensor.

37. A method for generating at least one electrical voltage for at least one electrical load comprising:

regularly reconfiguring an electrical connectivity of at least two battery subportions by subsequently changing between at least the following switching states using at least two electric switches per battery subportion;

a first battery subportion is electrically conductively connected in series to at least one second battery subportion, and

the at least one battery subportion is not electrically conductively connected to any other battery subportion,

wherein each of the at least two battery subportions comprises at least one electronic controller which turns a battery subportion off by changing a connectivity of the battery subportion to the other battery subportion in such a way that the battery subportion is not forming a closed electric circuit with at least one other battery subportion or at least one load so that said battery subportion is not involved in external current flow, if an emergency event is detected by said at least one electronic controller.

38. The method of claim 37, wherein the method generates said at least one electrical voltage by subsequently changing between at least the following switching states using at least two electric switches per battery subportion:

a first battery subportion is electrically conductively connected in series to at least one second battery subportion;

the at least one first battery subportion is electrically conductively connected in parallel to at least one second battery subportion; and

the at least one battery subportion is not electrically conductively connected to any other battery subportion.

39. The method of claim 37, wherein at least one of said at least one electrical voltage is changing over time.

40. The method of claim 37, wherein at least one of said at least one electrical voltage contains sinusoidal segments.

41. The method of claim 37, further comprising generating at least three electrical voltages containing sinusoidal segments forming a three-phase system.

42. The method of claim 37, wherein the at least one electrical load is an electrical machine.

43. The method of claim 37, wherein the at least one electrical load is an auxiliary power supply bus.

44. The method of claim 37, wherein said emergency event is detected by said at least one electronic controller if at least one current sensor detecting the current flowing into at least one battery subportion and connected to said at least one electronic controller exceeds a predefined threshold.

45. The method of claim 37, wherein said emergency event is detected by said at least one electronic controller if at least one voltage sensor detecting the voltage of at least one battery subportion and connected to said at least one electronic controller exceeds or falls below a predefined threshold.

46. The method of claim 37, wherein said emergency event is detected by said at least one electronic controller if a binary logic combination of at least one of the following conditions is true:

(a) the voltage of at least one electrical energy storage element is lower than a predefined first level;

(b) the voltage of at least one electrical energy storage element is higher than a predefined second level;

(c) the current flowing through at least one electrical energy storage element is higher than a predefined third level;

(d) a time derivative of the voltage of at least one electrical energy storage element is higher than a predefined fourth level;

(e) a temperature of at least one electrical energy storage element is higher than a predefined fifth level;

(g) an acceleration detected by at least one acceleration sensor is higher than a predefined sixth level.

47. The method of claim 37, wherein an electric charging current or electric charging voltage provided by at least one external electric charging source is controlled by reconfiguring the electrical connectivity of at least two battery subportions to charge the at least two battery subportions.

48. The method of claim 47, wherein the at least one external electric charging source is connected before charging begins by closing at least one electrical switch and disconnected after charging ends by opening said at least one electrical switch.