Combined motor drive and battery recharge system

• US 5,341,075 A
• Filed: 03/10/1993
• Issued: 08/23/1994
• Est. Priority Date: 03/10/1993
• Status: Expired due to Term

• Current Assignee: AC Propulsion, Inc.
• Original Assignee: AC Propulsion, Inc.
• Inventors: Cocconi, Alan G.
• Primary Examiner(s): SALATA, ANTHONY J
• Application Number:
  US08/028,998
• Time in Patent Office: 531 Days
• Field of Search: 318/139, 318/727, 318/729, 318/41, 318/105, 318/376, 318/799-812, 307/64, 307/66, 307/67, 307/68, 307/45, 307/46, 307/48, 363/55, 363/56, 363/26, 363/37
• US Class Current: 318/139
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• 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

Abstract

A combined battery recharge and motor drive system employs an essentially conventional polyphase pulse width modulated (PWM) inverter and a polyphase motor which may be reconnected to operate in a battery recharge mode. Single phase or three-phase AC power from an external source is applied across the reconfigured circuit, and the inverter switches are then controlled to operate as a boost switching regulator. Electrostatic (Faraday) shielding techniques and construction allow extremely small ground currents for improved safety an GFI outlet compatibility.

Claims

1. An integrated motor drive and power source recharging system comprising:

a polyphase electric motor having a plurality of motor windings;

a rechargeable DC power source having a positive terminal and a negative terminal;

a plurality of bi-directional switching means for supplying electrical current to respective ones of the plurality of motor windings in a drive mode, each of the switching means having positive and negative terminals coupled in parallel to the positive and negative terminals of the DC power source, respectively, each of the switching means further having a center terminal coupled to a respective one of the motor windings in the drive mode;

an AC port having first and second terminals for connection to a source of AC electrical power;

first contactor means for selectively decoupling the center terminal of a first one of the plurality of switching means from its respective first motor winding in any mode other than the drive mode;

second contactor means for selectively coupling the first terminal of the AC port to the center terminal of the first switching means and the second terminal of the AC port to the first motor winding in a recharge mode so as to incorporate the first motor winding as an inductive circuit element in a recharging circuit;

switch control means for operating the plurality of switching means as a polyphase inverter in the drive mode and for operating at least the first switching means as a switching regulator in the recharge mode.

2. The system of claim 1 wherein the motor is a three phase induction motor.

3. The system of claim 1 wherein the switch control means operates the first switching means and one other of the plurality of switching means in combination as a switching regulator in the recharge mode.

4. The system of claim 1 wherein the second contactor means couples the first terminal of the AC port to the center terminal of the first switching means and the second terminal of the AC port to the first motor winding in an AC power generation mode and wherein the switch control means operates at least the first switching means as a DC power inverter in the power generation mode.

5. The system of claim 1 further comprising electrostatic shielding means for reducing capacitive coupling between circuit components of the system and a chassis ground, thereby reducing ground currents.

6. The system of claim 1 wherein said switch control means comprises means for operating the plurality of switching means in a power supply mode, in which the second contactor means is operative as in the recharge mode, for generating AC power from the DC power source and supplying the AC power to the AC port.

7. The system of claim 1 wherein said switch control means comprises means for operating the plurality of switching means in a discharge mode, in which the second contactor means is operative as in the recharge mode, for discharging the DC power source into the source of AC electrical power.

8. An integrated motor drive and power source recharging system comprising:

a polyphase electric motor having a plurality of motor windings;

a rechargeable battery having a positive terminal and a negative terminal;

a plurality of paired solid state switching elements for supplying electrical current to respective ones of the plurality of motor windings in a drive mode, each of the paired switching elements having positive and negative terminals coupled in parallel to the positive and negative terminals of the battery, respectively, each of the paired switching elements further having a center terminal coupled to a respective one of the motor windings in the drive mode;

an AC port having first and second terminals for connection to a source of AC electrical power;

a first relay for selectively decoupling the center terminal of a first one of the plurality of paired switching elements from its respective first motor winding in any mode other than the drive mode;

a second relay for selectively coupling the first terminal of the AC port to the center terminal of the first pair of switching elements and the second terminal of the AC port to the first motor winding in a recharge mode so as to incorporate the first motor winding as an inductive circuit element in a recharging circuit;

a switch control electronics unit for operating the plurality of paired switching elements as a polyphase inverter in the drive mode and for operating at least the first pair of switching elements as a switching regulator in the recharge mode.

9. The system of claim 8 wherein the motor is a three phase induction motor.

10. The system of claim 8 wherein the switch control electronics unit operates the first pair of switching elements and one other pair of the plurality of paired switching elements in combination as a switching regulator in the recharge mode.

11. The system of claim 8 wherein the second relay couples the first terminal of the AC port to the center terminal of the first pair of switching elements and the second terminal of the AC port to the first motor winding in an AC power generation mode and wherein the switch control electronics unit operates at least the first pair of switching elements as a DC power inverter in the power generation mode.

12. The system of claim 8 further comprising electrostatic shielding means for reducing capacitive coupling between circuit components of the system and a chassis ground, thereby reducing ground currents.

13. The system of claim 8 wherein said switch control electronics unit comprises means for operating the plurality of paired switching elements in a power supply mode, in which the second relay is operative as in the recharge mode, for generating AC power from the battery and supplying the AC power to the AC port.

14. The system of claim 8 wherein said switch control electronics unit comprises means for operating the plurality of paired switching elements in a discharge mode, in which the second relay is operative as in the recharge mode, for discharging the battery into the source of AC electrical power.

15. In an electric motor traction system having a polyphase induction motor coupled to a polyphase bridge inverter for generating polyphase motor current signals from a DC power source, a method for recharging the DC power source comprising the steps of:

decoupling a first phase of the polyphase bridge inverter from a corresponding first motor winding;

coupling a first terminal of an AC power source to the first phase of the polyphase bridge inverter;

coupling a second terminal of the AC power source to the first motor winding so as to incorporate the first motor winding as an inductive circuit element in a recharging circuit;

controlling the polyphase bridge inverter to operate as a switching regulator to apply a DC charging voltage to the DC power source.

16. An integrated motor drive and power source recharging system comprising:

a polyphase electric motor having at least three motor windings, each having first and second terminals;

a rechargeable DC power source having a positive terminal and a negative terminal;

a plurality of bi-directional switching means equal in number to the number of motor windings for supplying electrical current to respective ones of the motor windings in a drive mode, each of the switching means having positive and negative terminals coupled in parallel to the positive and negative terminals of the DC power source, respectively, each of the switching means further having a center terminal coupled to the first terminal of a respective one of the motor windings;

an AC port having first, second and third terminals for connection to a source of AC electrical power;

first contactor means for selectively coupling the second terminal of a first and second motor winding to the second terminal of each of the remaining motor windings in the drive mode;

second contactor means for selectively coupling, in a recharge mode, the first terminal of the AC port to the second terminal of the first motor winding, the second terminal of the AC port to the second terminal of the second motor winding, and the third terminal of the AC port to the second terminal of at least one of the remaining motor windings so as to incorporate the first and second motor windings and said at least one of the remaining motor windings as inductive circuit elements in a recharging circuit;

switch control means for operating the plurality of switching means as a polyphase inverter in the drive mode and for operating at least the first and second switching means as a switching regulator in the recharge mode.