Multistage Power Supply System and Method for Providing Uninterrupted Power to Vehicle Circuitry

• US 20130026827A1
• Filed: 07/28/2011
• Published: 01/31/2013
• Est. Priority Date: 07/28/2011
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Hampo, Richard J., Klesyk, Krzysztof, Liao, Jingsheng
• Granted Patent: US 9,211,798 B2
• Time in Patent Office: Days
• US Class Current: 307/10.1
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 58/20 having different nominal voltages
• 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

Abstract

A multistage power supply system and method for providing uninterrupted low voltage electrical power to control circuitry in an electric or hybrid-electric vehicle. A first stage includes a converter for receiving a low voltage input from a vehicle battery and converting the vehicle battery low voltage input to a high voltage output. A second stage provided in series communication with the first stage includes a converter for receiving one of a rectified AC high voltage input and the first stage high voltage output and converting the one of the rectified AC high voltage input and the first stage high voltage output to a low voltage output for use in powering the vehicle control circuitry. The low voltage output is produced by the second stage from the rectified AC high voltage input when the rectified AC high voltage input is present, and the low voltage output is produced by the second stage from the first stage high voltage output when the rectified AC high voltage input is absent.

Claims

1. A multistage power supply system for providing uninterrupted low voltage electrical power to control circuitry in an electric or hybrid-electric vehicle, the system comprising:

a first stage comprising a converter for receiving a low voltage input from a vehicle battery and converting the vehicle battery low voltage input to a high voltage output; and

a second stage provided in series communication with the first stage, the second stage comprising a converter for receiving one of a rectified AC high voltage input and the first stage high voltage output and converting the one of the rectified AC high voltage input and the first stage high voltage output to a low voltage output for use in powering the vehicle control circuitry;

wherein the low voltage output is produced by the second stage from the rectified AC high voltage input when the rectified AC high voltage input is present, and the low voltage output is produced by the second stage from the first stage high voltage output when the rectified AC high voltage input is absent.

2. The system claim 1 wherein the rectified AC high voltage input is produced as an output by a bulk power source, the rectified AC high voltage input has a minimum value, the first stage converter is provided in communication with the bulk power source output, and the first stage converter has a setpoint less than the minimum value of the rectified AC high voltage input so that the first stage converter produces the first stage high voltage output in the absence of the rectified AC high voltage input.

3. The system of claim 2 wherein the bulk power source comprises a rectifier for rectifying an AC high voltage input received from an AC power line.

4. The system of claim 1 wherein the vehicle battery low voltage input comprises a 12 volt DC input and the first stage high voltage output comprises a 100 volt DC output.

5. The system of claim 1 wherein the low voltage output for use in powering the vehicle control circuitry comprises a 5 volt DC output.

6. The system of claim 1 wherein the low voltage output comprises a plurality of low voltage outputs for use in powering a plurality of controllers, a first one of the plurality of low voltage outputs for powering a first controller for use in primary control operations, a second one of the plurality of low voltage outputs for powering a second controller for use in low voltage control operations, and a third one of the plurality of low voltage outputs for powering a third controller for use high voltage control operations.

7. The system of claim 1 wherein the second stage converter comprises an isolated flyback converter.

8. The system of claim 1 wherein the first stage converter comprises a boost converter.

9. The system of claim 1 wherein the low voltage output produced by the second stage from the first stage high voltage output provides sufficient power to the vehicle control circuitry for the control circuitry to perform diagnostic operations.

10. The system of claim 1 wherein the low voltage output produced by the second stage from the first stage high voltage output provides sufficient power to the vehicle control circuitry to permit reprogramming thereof.

11. A method for providing uninterrupted low voltage electrical power to control circuitry in an electric or hybrid-electric vehicle having a multistage power supply, the method comprising:

receiving a low voltage input from a vehicle battery;

converting the vehicle battery low voltage input to a high voltage output;

receiving one of a rectified AC high voltage input and the high voltage output; and

converting the one of the rectified AC high voltage input and the high voltage output to a low voltage output for use in powering the vehicle control circuitry;

wherein the low voltage output is produced from the rectified AC high voltage input when the rectified AC high voltage input is present, and the low voltage output is produced from the high voltage output when the rectified AC high voltage input is absent.

12. The method of claim 11 further comprising providing a multistage power supply system comprising a first stage and a second stage provided in series communication with the first stage, wherein receiving the vehicle battery low voltage input and converting the vehicle battery low voltage input to a high voltage output is performed by the first stage of the multistage power supply system, and wherein receiving one of a rectified AC high voltage input and the high voltage output and converting the one of the rectified AC high voltage input and the high voltage output to a low voltage output is performed by the second stage of the multistage power supply system.

13. The method of claim 12 wherein the rectified AC high voltage input is produced as an output by a bulk power source, the rectified AC high voltage input has a minimum value, the first stage comprises a converter provided in communication with the bulk power source output, and the first stage converter has a setpoint less than the minimum value of the rectified AC high voltage input so that the first stage converter produces the first stage high voltage output in the absence of the rectified AC high voltage input.

14. The method of claim 13 wherein the bulk power source comprises a rectifier for rectifying an AC high voltage input received from an AC power line.

15. The method of claim 11 wherein the vehicle battery low voltage input comprises a 12 volt DC input and the first stage high voltage output comprises a 100 volt DC output.

16. The method of claim 11 wherein the low voltage output for use in powering the vehicle control circuitry comprises a 5 volt DC output.

17. The method of claim 11 wherein the low voltage output comprises a plurality of low voltage outputs for use in powering a plurality of controllers, a first one of the plurality of low voltage outputs for powering a first controller for use in primary control operations, a second one of the plurality of low voltage outputs for powering a second controller for use in low voltage control operations, and a third one of the plurality of low voltage outputs for powering a third controller for use high voltage control operations.

18. The method of claim 11 further wherein the second stage comprises an isolated flyback converter.

19. The method of claim 11 wherein the first stage converter comprises a boost converter.

20. The method of claim 11 wherein the low voltage output produced by the second stage from the first stage high voltage output provides sufficient power to the vehicle control circuitry for the control circuitry to perform diagnostic operations or to permit reprogramming of the control circuitry.