Battery charging system for electric vehicles

• US 5,633,577 A
• Filed: 06/06/1995
• Issued: 05/27/1997
• Est. Priority Date: 06/06/1994
• Status: Expired due to Fees

• Current Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Original Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Inventors: Matsumae, Hiroshi, Ooyama, Yoshihiko, Banzai, Keiichiro
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US08/467,999
• Time in Patent Office: 721 Days
• Field of Search: 322/25, 322/28, 322/29, 363/37, 307/66, 320/5, 320/2
• US Class Current: 322/37
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02M 3/33573 Full-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A battery charger includes a primary side circuit, a transformer, a secondary side circuit and a control circuit. The secondary side circuit includes a first output unit and a second output unit. The battery charges a main battery and an auxiliary battery. The first output unit, which is connected to a main battery, includes an integrated rectifier-converter and a smoothing circuit. The integrated rectifier-converter is formed using MOSFETs. When charging the auxiliary battery with power from the main battery, power from the main battery is converted by the integrated rectifier-converter to AC power which induces power in an output winding of a transformer connected to the auxiliary battery.

Claims

1. A battery charging system comprising:

a main battery for driving a vehicle;

an auxiliary battery for driving an auxiliary device of the vehicle, the battery charging system charging the main battery and the auxiliary battery when a supply of electric power is received from a commercial AC power source;

a rectification circuit for rectifying electric power from the commercial AC power source;

a converter for converting the rectified electric power to AC input power;

a transformer to transform the AC input power, the transformer including an output winding having a first part to output first AC power and a second part to output second AC power;

a first output part, connected to the first part of the output winding of the transformer, to rectify the first AC power and to supply the first AC power to the main battery; and

a second output part, connected to the second part of the output winding of the transformer, to rectify the second AC power and to supply the second AC power to the auxiliary battery; and

a converting Circuit, included in the first output part, to convert, when the battery charging system does not receive the electric power from the commercial AC power source, electric power of the main battery to the second AC power to provide electric power from the main battery to the auxiliary battery through the first part and the second part of the output winding.

2. A battery charging system for an electric vehicle, the battery charging system comprising:

a rectification circuit for rectifying electric power from a commercial AC power source;

a DC/AC converter for converting the rectified electric power into AC input power;

a transformer for stepping up/down an output from the DC/AC converter, the transformer including a first output winding and a second output winding;

a first output part, connected to the first output winding, comprised of a rectifying device which rectifies a first output voltage of the first output winding by allowing current to flow bidirectionally therethrough, the first output part outputting the rectified first output voltage of the first output winding to a main battery of the electric vehicle when electric power is supplied from the commercial AC power source, and, when the battery charging system does not receive the electric power from the commercial AC power source, the first output part converting DC voltage of the main battery to regenerated AC voltage and applying the regenerated AC voltage to the first output winding to induce a second output voltage in the second output winding; and

a second output part, connected to the second output winding, to rectify the second output voltage and output the second output voltage to the auxiliary battery for driving an auxiliary electric load.

3. The battery charging system for an electric vehicle according to claim 2, wherein the bidirectional device of the first output part comprises:

a plurality of MOSFETs.

4. The battery charging system for an electric vehicle according to claim 2, wherein the bidirectional device of the first output part comprises:

a rectifying device; and

a switching device connected in parallel with the rectifying device;

the bidirectional device performing high-frequency AC conversion by switching the switching device when the auxiliary battery is charged with an input of electric power from the main battery.

5. The battery charging system for an electric vehicle according to claim 4, wherein:

the switching device is switched in synchronization with switching of the DC/AC converter; and

the switching device rectifies the output voltage of the first output part of the output winding of the transformer jointly with the rectifying device.

6. The battery charging system for an electric vehicle according to claim 2, further comprising:

a smoothing circuit disposed between the first output part and the main battery, the smoothing circuit comprising;

a smoothing coil, and

a smoothing capacitor for smoothing the rectified first output voltage, the smoothing circuit outputting the smoothed rectified first output voltage to the main battery.

7. The battery charging system for an electric vehicle according to claim 6, further comprising:

first switching means connected in parallel with the smoothing coil to short-circuit the smoothing coil when the auxiliary battery is charged with electric power from the main battery.

8. The battery charging system for an electric vehicle according to claim 6, further comprising:

second switching means for switching the smoothing capacitor to a first output side of the second switching means when the auxiliary battery is charged with an input of electric power from the main battery.

9. The battery charging system for an electric vehicle according to claim 2, wherein the second output part comprises:

a first rectification device;

a second rectification device; and

a switch for opening/closing a connection between output terminals of the first rectification device and the second rectification device.

10. The battery charging system for an electric vehicle according to claim 9, wherein:

a ratio of a number of windings T2 for the first output part of the transformer to a number of windings T3 for the second output part is set to be T2;

T3≈

m;

2, where a number of batteries composing the auxiliary battery is 1 and a number of batteries composing the main battery is m.

17. The battery charging system for an electric vehicle according to claim 4, wherein at least one of the rectifying device and the switching device comprise:

a plurality of MOSFETs.

18. The battery charging system for an electric vehicle according to claim 4, wherein at least one of the rectifying device and the switching device comprise:

a plurality of transistors; and

a plurality of diodes.

19. The battery charging system for an electric vehicle according to claim 2, wherein the second output part comprises:

a first rectification device; and

a second rectification device.

20. The battery charging system for an electric vehicle according to claim 19, the battery charging system further comprising:

a smoothing circuit disposed between the second output part and the auxiliary battery, the smoothing circuit comprising;

a smoothing coil, and

a smoothing capacitor for smoothing the rectified second output voltage, the smoothing circuit outputting the smoothed rectified second output voltage to the auxiliary battery.

21. The battery charging system for an electric vehicle according to claim 4, wherein the second output part comprises:

a first rectification device; and

a second rectification device.

22. The battery charging system for an electric vehicle according to claim 4, the battery charging system further comprising:

a smoothing circuit disposed between the second output part and the auxiliary battery, the smoothing circuit comprising;

a smoothing coil, and

a smoothing capacitor for smoothing the rectified second output voltage, the smoothing circuit outputting the smoothed rectified second output voltage to the auxiliary battery.

11. A battery charging system for an electric vehicle comprising:

an inductive coupler provided with a primary coil and a secondary coil separable from each other for stepping up/down voltage supplied to the primary coil and outputting the same to a secondary coil side;

a first output part comprised of a bidirectional device which can bidirectionally flow current for rectifying an output voltage of a first part of the secondary coil of the inductive coupler and outputting the same to the main battery for driving the vehicle when electric power is supplied to the primary coil of the inductive coupler, and performing high-frequency AC conversion when the auxiliary battery is charged with an input of electric power from the main battery; and

a second output part for rectifying an output voltage of a second part of the secondary coil of the inductive coupler and outputting the same to an auxiliary battery for driving an auxiliary electric load.

12. The battery charging system for an electric vehicle according to claim 11, wherein:

the inductive coupler is comprised of a housing in which the primary coil is insulated with an insulating material, a primary coil winding disposed within the housing and an electric cable connected to the primary coil winding for coupling electric power from an external electric power source;

the secondary coil is comprised of a first magnetic core part and a second magnetic core part which can be coupled with each other and a third magnetic core provided between the first magnetic core and the second magnetic core, and comprises recessed parts which enable the primary coil to be inserted thereinto between the first magnetic core part and the third magnetic core part and between the second magnetic core part and the third magnetic core part respectively;

the primary coil and the secondary coil are so constructed as to form a transformer when the primary coil and the secondary coil are coupled with each other; and

the first secondary coil is operated as a primary coil to form a transformer when the primary coil and the secondary coil are separated from each other.

13. The battery charging system for an electric vehicle according to claim 12, wherein:

the inductive coupler comprises an opening/closing means for opening/closing the first, second and third magnetic core parts.

14. The battery charging system for an electric vehicle according to claim 13, wherein the opening/closing means comprises:

a means for positioning the first, second and third magnetic core parts in the opened or closed position by moving a movable member to which the upper first magnetic core part is attached and a movable member to which the second magnetic core part is attached to enable the movable parts to sandwich the third magnetic core part from upper and below; and

a spring means coupled with the movable member for holding the first, second and third magnetic core parts in the coupled state when the first, second and third magnetic core parts are coupled in the closed position.

15. The battery charging system for an electric vehicle according to claim 13, further comprising:

a magnetic body to be inserted into the recessed part when the primary coil and the secondary coil are separated from each other.

16. The battery charging system for an electric vehicle according to claim 15, wherein:

the magnetic body is made of ferrite for high frequency.

23. A battery charging system comprising:

a transformer having a primary winding on a primary side and a first secondary winding and a second secondary winding on a secondary side;

a first rectification circuit, connected to a connection for a commercial AC power source, to convert commercial AC power to a DC voltage;

a DC/AC converter, connected to the primary winding of the transformer, to convert the DC voltage to AC input power;

a rectification/converting device, connected to the first secondary winding of the transformer, to rectify AC voltage across the first secondary winding, when electric power is supplied from the commercial AC power source, to charge a main battery, and to convert DC voltage from the main battery to regenerated AC power, when the battery charging system does not receive the electric power from the commercial AC power source, and applying the regenerated AC voltage to the first secondary winding of the transformer to induce a second AC voltage in the second secondary winding; and

a second rectification device, connected to the second secondary winding, to rectify the second AC voltage across the second secondary winding and to output the rectified second AC voltage to the auxiliary battery.