POWER PROCESSING SYSTEMS AND METHODS FOR USE IN PLUG-IN ELECTRIC VEHICLES

• US 20100013438A1
• Filed: 07/21/2008
• Published: 01/21/2010
• Est. Priority Date: 07/21/2008
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (General Motors Company)
• Inventors: ANWAR, Mohammad N., MESE, Erkan
• Granted Patent: US 8,183,820 B2
• Time in Patent Office: Days
• US Class Current: 320/138
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2210/20 AC to AC 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 2220/54 Windings for different functions
• 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 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: B60L 53/63 in response to network capacity
• CPC Class Codes: B60L 53/64 Optimising energy costs, e.g. responding to electricity rates
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 55/00 Arrangements for supplying energy stored within a vehicle to a power network, i.e. vehicle-to-grid [V2G] arrangements
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• 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 10/126 : the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing
• CPC Class Codes: Y10S 903/906 : Motor or generator
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

Embodiments include a power processing system and methods of its operation in a plug-in electric vehicle. The power processing system includes at least one AC electric motor, a bi-directional inverter system, and an electronic control system. The electronic control system provides a drive function by providing first control signals to the bi-directional inverter system which, in response, draws DC electrical power from a DC energy source, converts the DC power to AC power, and provides the AC power to windings of the at least one AC electric motor. The electronic control system also provides a charging function by providing second control signals to the bi-directional inverter system which, in response, draws AC power from the windings of the at least one AC electric motor, converts the AC power to DC power, and provides the DC power to the DC energy source in order to recharge the DC energy source.

Claims

1. A power processing system for use in a plug-in electric vehicle, the system comprising:

at least one alternating current (AC) electric motor having windings;

a bi-directional inverter system, electrically coupled with the at least one AC electric motor, the bi-directional inverter system including a plurality of switches; and

an electronic control system, electrically coupled with the bi-directional inverter system, wherein the electronic control system is operable to provide a drive function by providing first control signals to the bi-directional inverter system to cause the bi-directional inverter system to draw direct current (DC) electrical power from a DC energy source of the vehicle, to convert the DC power to AC power, and to provide the AC power to the windings of the at least one AC electric motor in order to propel the vehicle, and wherein the electronic control system is further operable to provide a charging function by providing second control signals to the bi-directional inverter system to cause the bi-directional inverter system to draw AC power from the windings of the at least one AC electric motor, to convert the AC power to DC power, and to provide the DC power to the DC energy source in order to recharge the DC energy source.

2. The system of claim 1, further comprising:

an AC power interface electrically coupled with the at least one AC electric motor, wherein the AC power interface is a hardware interface selected from a group of hardware interfaces that includes a two-conductor AC power interface, a three-conductor AC power interface, a single-phase junction box, a two-phase junction box, a three-phase junction box, a single-phase plug, a two-phase plug, and a three-phase plug.

3. The system of claim 1, further comprising:

an AC power interface adapted to be electrically connected with an external load, and

wherein the electronic control system is further operable in a power processing mode to provide third control signals to the bi-directional inverter system to cause the bi-directional inverter system to draw DC power from the DC energy source, to convert the DC power to AC power, and to provide the AC power to the windings of the at least one AC electric motor in order to provide AC power to the external load through the AC power interface.

4. The system of claim 3, wherein the external load includes an electricity-consuming device, and wherein the electronic control system is operable in the power processing mode to provide an AC power source function by providing the third control signals.

5. The system of claim 3, wherein the external load includes an electric utility, and wherein the electronic control system is operable in the power processing mode to provide a utility-interconnected active power generator function by providing the third control signals.

6. The system of claim 3, wherein the external load includes an electric utility, and wherein the electronic control system is operable in the power processing mode to provide a utility-interconnected reactive power generator function by providing the third control signals during a first half of an electrical cycle, and by providing fourth control signals during a second half of the electrical cycle to cause the bi-directional inverter system to draw AC power from the external load via the windings of the at least one AC electric motor, to convert the AC power to DC power, and to provide the DC power to the DC energy source.

7. The system of claim 3, wherein the external load includes an electric utility, and wherein the electronic control system is operable in the power processing mode to provide a utility-interconnected active power filter function by providing the third control signals to cause the bi-directional inverter system to draw DC power from the DC energy source, to convert the DC power to AC power, and to provide the AC power to the windings of the at least one AC electric motor in order to supply the AC power to the electric utility to assist the electric utility in creating more sinusoidal voltage/current waveforms.

8. The system of claim 1, wherein

the bi-directional inverter system includes a first inverter section and a second inverter section, and wherein

the at least one AC electric motor includes a first motor and a second motor, wherein the first motor has a first neutral point and first motor windings with first ends and second ends, and the second motor has a second neutral point and second motor windings with first ends and second ends, and wherein

the system further comprises:

a two-conductor AC power interface;

a first conductor between the first motor and the AC power interface; and

the second conductor between the second motor and the AC power interface, wherein

the first ends of the first motor windings are electrically coupled with the first inverter section, and the first neutral point is adapted to be electrically coupled with the first conductor between, and wherein the first ends of the second motor windings are electrically coupled with the second inverter section, and the second neutral point is adapted to be electrically coupled with the second conductor.

9. The system of claim 1, wherein the bi-directional inverter system includes a first inverter section, and wherein the at least one AC electric motor includes a first motor having windings with first ends and second ends, wherein the first ends of the windings are electrically coupled with the first inverter section, and wherein the system further comprises:

a three-conductor AC power interface;

a switch array having a plurality of switches; and

three conductors between the switch array and the three conductor AC power interface, wherein

the second ends of the windings of the first motor each are electrically coupled to a switch of the switch array, and when the plurality of switches of the switch array are in a first position, the second ends are interconnected to form a neutral point of the first motor, and when the switches of the switch array are in a second position, each of the second ends are electrically coupled with one of the three conductors between the switch array and the three-conductor AC power interface.

10. The system of claim 1, wherein

the bi-directional inverter system includes a first inverter section, a second inverter section, and a third inverter section, and wherein

the at least on AC electric motor includes a first motor having a first neutral point and first motor windings with first ends and second ends, a second motor having a second neutral point and second motor windings with first ends and second ends, and a third motor having a third neutral point and third motor windings with first ends and second ends, and

the system further comprises:

a three-conductor AC power interface;

a first conductor between the first motor and the AC power interface;

a second conductor between the second motor and the AC power interface; and

a third conductor between the third motor and the AC power interface, wherein

the first ends of the first motor windings are electrically coupled with the first inverter section, and the first neutral point of the first motor is adapted to be electrically coupled with the first conductor, the first ends of the second motor windings are electrically coupled with the second inverter section, and the second neutral point of the second motor is adapted to be electrically coupled with the second conductor, and the first ends of the third motor windings are electrically coupled with the third inverter section, and the third neutral point of the third motor is adapted to be electrically coupled with the third conductor.

11. The system of claim 1, wherein

the bi-directional inverter system includes a first inverter section and a second inverter section, and wherein

the at least one AC electric motor includes a first motor and a second motor, wherein the first motor has a first neutral point and first motor windings with first ends and second ends, and the second motor has second motor windings with first ends and second ends, and wherein

the system further comprises:

a three-conductor AC power interface;

a plurality of DC bus capacitors having a connection point therebetween, wherein the plurality of DC bus capacitors is electrically coupled in parallel with the bi-directional inverter system;

an inductor electrically coupled to the connection point between the plurality of DC bus capacitors;

a first conductor electrically coupled between the inductor and the AC power interface;

a second conductor electrically coupled between the first motor and the AC power interface; and

a third conductor between the second motor and the AC power interface, wherein

the first ends of the first motor windings are electrically coupled with the first inverter section, and the first neutral point is adapted to be electrically coupled with the second conductor, and wherein the first ends of the second motor windings are electrically coupled with the second inverter section, and the second neutral point is adapted to be electrically coupled with the third conductor.

12. The system of claim 1,

the inverter system includes a first inverter section and a second inverter section, and wherein

the at least one AC electric motor includes a first motor and a second motor, wherein the first motor includes a first neutral point and first motor windings with first ends and second ends, and the second motor includes a second neutral point and second motor windings with first ends and second ends,

the system further comprising:

a three-conductor AC power interface;

a half bridge electrically coupled in parallel with the bi-directional inverter system, wherein the half bridge includes at least two switches connected in series and a connection point between the at least two switches;

an inductor electrically coupled to the connection point between the at least two switches;

a first conductor electrically coupled between the inductor and the AC power interface;

a second conductor electrically coupled between the first motor and the AC power interface; and

a third conductor electrically coupled between the second motor and the AC power interface, wherein

the first ends of the first motor windings are electrically coupled with the first inverter section, the first neutral point is adapted to be electrically coupled with the second conductor, the first ends of the second motor windings are electrically coupled with the second inverter section, and the second neutral point of the second motor is adapted to be electrically coupled with the third conductor.

13. The system of claim 1,

the inverter system includes a first inverter section and a second inverter section, and

the at least one AC electric motor includes a first motor and a second motor, wherein the first motor includes a first neutral point and first motor windings having first ends and second ends, and the second motor includes a second neutral point and second motor windings that include a first second motor winding, a second second motor winding, and a third second motor winding, wherein the second motor windings have first ends and second ends, and wherein

the system further comprises:

a three-conductor AC power interface;

a switch adapted to be switched between a first position and a second position;

a first conductor between the first motor and the AC power interface;

a second conductor between the second motor and the AC power interface; and

a third conductor between the second motor and the AC power interface, wherein

the first ends of the first motor windings are electrically coupled with the first inverter section, and the first neutral point is adapted to be electrically coupled with the first conductor, the first ends of the second motor windings are electrically coupled with the second inverter section, and a second end of the first second motor winding is electrically coupled with the switch, wherein the second end of the first second motor winding also is electrically coupled with a second end of the second second motor winding and a second end of the third second motor winding when the switch is in the first position, and wherein the second end of the first second motor winding is electrically coupled with the second conductor when the switch is in the second position, and wherein the second end of the second second motor winding and the second end of the third second motor winding are electrically coupled together to form the second neutral point.

14. A power processing system for use in a plug-in electric vehicle, the system comprising:

at least one alternating current (AC) electric motor having windings; and

a bi-directional inverter system electrically coupled with the at least one AC electric motor, the bi-directional inverter system including a plurality of switches, wherein the bi-directional inverter system is adapted cause the system to provide a drive function by drawing direct current (DC) electrical power from a DC energy source of the vehicle in response to receiving first control signals, converting the DC power to AC power, and providing the AC power to the windings of the at least one AC electric motor in order to propel the vehicle, and wherein the bi-directional inverter system is adapted cause the system to provide a charging function by drawing AC power from the windings of the at least one AC electric motor in response to receiving second control signals, converting the AC power to DC power, and providing the DC power to the DC energy source in order to recharge the DC energy source.

15. The system of claim 14, further comprising:

an AC power interface adapted to electrically connect with an external load in the form of an electricity-consuming device, and

wherein the bi-directional inverter system is further adapted cause the system to provide an AC power source function by drawing DC power from the DC energy source in response to third control signals, converting the DC power to AC power, and providing the AC power to the windings of the at least one AC electric motor in order to provide AC power to the electricity-consuming device.

16. The system of claim 14, further comprising:

an AC power interface adapted to electrically connect with an external load in the form of an electric utility, and

wherein the bi-directional inverter system is further adapted cause the system to provide a utility-interconnected active power generator function by drawing DC power from the DC energy source in response to third control signals, converting the DC power to AC power, and providing the AC power to the windings of the at least one AC electric motor in order to provide AC power to the electric utility.

17. The system of claim 14, further comprising:

an AC power interface adapted to electrically connect with an external load in the form of an electric utility, and

wherein the bi-directional inverter system is further adapted cause the system to provide a utility-interconnected reactive power generator function by drawing DC power from the DC energy source in response to third control signals during a first half of an electrical cycle, converting the DC power to AC power during the first half of the electrical cycle, and providing the AC power to the windings of the at least one AC electric motor in order to provide AC power to the electric utility during the first half of the electrical cycle, and drawing AC power from the electric utility via the windings of the at least one AC electric motor in response to fourth control signals during a second half of the electrical cycle, converting the AC power to DC power during the second half of the electrical cycle, and providing the DC power to the DC energy source during the second half of the electrical cycle.

18. The system of claim 14, further comprising:

an AC power interface adapted to electrically connect with an external load in the form of an electric utility, and

wherein the bi-directional inverter system is further adapted cause the system to provide a utility-interconnected active power filter function by drawing DC power from the DC energy source in response to third control signals, converting the DC power to AC power, and providing the AC power to the windings of the at least one AC electric motor in order to supply the AC power to the electric utility to assist the electric utility in creating more sinusoidal voltage/current waveforms.

19. A method for operating a power processing system of a plug-in electric vehicle, the method comprising the steps of:

providing first control signals to a bi-directional inverter system of the vehicle, during a first time period, which cause the bi-directional inverter system to draw direct current (DC) electrical power from a DC energy source of the vehicle in response to the first control signals, to convert the DC power to alternating current (AC) power, and to provide the AC power to windings of at least one AC electric motor of the vehicle in order to propel the vehicle, thus providing a drive function; and

providing second control signals to the bi-directional inverter system, during a second time period, which cause the bi-directional inverter system to draw AC power from the windings of the at least one AC electric motor in response to receiving the second control signals, to convert the AC power to DC power, and to provide the DC power to the DC energy source in order to recharge the DC energy source, thus providing a charging function.

20. The method of claim 19, further comprising:

providing third control signals to the bi-directional inverter system, during a third time period, which cause the bi-directional inverter system to draw DC power from the DC energy source in response to receiving the third control signals, to convert the DC power to AC power, and to provide the AC power to the windings of the at least one AC electric motor in order to provide AC power to an external load, thus providing a power processing mode.