Integrated DC electric controller/charger

• US 5,734,237 A
• Filed: 05/31/1996
• Issued: 03/31/1998
• Est. Priority Date: 03/07/1995
• Status: Expired due to Fees

• Current Assignee: Tenergy Corporation
• Original Assignee: Tenergy Corporation
• Inventors: Engel, Gabriel D.
• Primary Examiner(s): Cabeca, John W.
• Application Number:
  US08/657,821
• Time in Patent Office: 669 Days
• Field of Search: 318/254, 318/269, 318/138, 318/439, 318/139, 318/801, 318/800, 318/803, 318/268, 363/120, 363/127, 363/89, 363/147, 307/66, 307/64, 320/138, 320/139, 320/DIG. 10, 320/DIG. 11, 320/DIG. 27, 320/140
• US Class Current: 318/139
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• 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: H02J 7/14 for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• 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
• CPC Class Codes: Y10S 320/10 Nonbattery load controls charging

Abstract

A drive assembly for an electric vehicle comprises a D.C. electric motor and an integrated charger controller for controlling the D.C. electric motor in a drive mode of operation and for charging a battery in a charge mode of operation. The integrated charger/controller includes a power module, (ii) a step-down module, and (iii) a control circuit. During the charge mode of operation, the input of the power module is connected to an electric power source and the power module provides a D.C. current output. Selected switches of the control circuit connect the output of the power module to the input of a step-down module, and connect the output of the step-down module to the terminals of the battery to charge it during the drive mode of operation, selected switches of the control circuit connect the terminals of the battery to the input of the power module, and connect the output of the power module to the D.C. motor to control the D.C. motor.

Claims

1. A drive assembly including a D.C. electric motor and an integrated charger/controller for controlling said D.C. electric motor in a drive mode of operation and adapted to be connected to an electric power source for charging battery in a charge mode of operation comprising:

(a) a power module having an output and an input adapted to be connected to an associated electric power source during a charge mode of operation wherein said power module provides a D.C. current to said output;

(b) a step-down module having an input connected to said power module and an output adapted to be connected to terminals of an associated battery;

(c) a control circuit including switch means having a multiplicity of switches, said control circuit having

(i) a drive mode of operation during which selected ones of said switches selectively effect the connection of the terminals of the associated battery to said input of said power module and selected ones of said switches selectively effect the connection of said output of said power module to said D.C. motor whereby said power module controls the said D.C. motor, and

(ii) a charge mode of operation during which said input of said power module is adapted to be connected to the associated electric power source, selected ones of said switches selectively effect the connection of said output of said power module to said input of said step-down module, and said output of said step-down module is adapted to be connected to the terminals of the associated battery whereby the associated battery is charged.

2. The drive assembly according to claim 1 wherein said step-down module includes a transistor, a diode and an inductor, said transistor being connected in parallel with said diode and connected in series with said inductor.

3. The drive assembly according to claim 2 wherein said power module includes said transistor of said step-down module.

4. The drive assembly according to claim 1 wherein said power module is adapted to be connected to both a D.C. and an A.C. power source.

5. The drive assembly according to claim 1 wherein the power module is adapted to be connected to is a D.C. power source and to pass the D.C. current therethrough to said step-down module.

6. The drive assembly according to claim 1 wherein said power module is adapted to be connected to an A.C. power source and converts A.C. to D.C.

7. The drive assembly according to claim 6 wherein said power module is a programmable pulse width modulated converter.

8. The drive assembly according to claim 7 wherein said programmable pulse width modulated converter includes power transistors and a parallel/series switching system, said parallel/series switching system connects said power transistors in series during said charge mode of operation whereby said power transistors rectify the associated A.C. current input to said D.C. current output of said power module and said parallel/series switching system connects said power transistors in parallel during said drive mode of operation whereby said power transistors control the associated D.C. motor.

9. The drive assembly according to claim 6 wherein said power module includes a transformer, diodes and transistors, whereby said transformer reduces the associated A.C. power source input voltage, said diodes rectify the A.C. current input to said D.C. current output of said power module and said transistors control said D.C. motor.

10. The drive assembly according to claim 6 wherein said step-down module includes a transistor, a diode and a first inductor, said transistor being connected in parallel with said diode and connected in series with said first inductor, a second inductor connected between said transistor of said step-down module and said diode of said step-down module, said second inductor connected in series with said transistor and connected in parallel with said diode whereby said second inductor corrects the power factor of the associated A.C. power input.

11. The drive assembly according to claim 6 wherein said step-down module includes a transistor, a diode and an inductor, said transistor being connected in parallel with said diode and connected in series with said inductor, a capacitor connected in parallel with said battery and said diode of said step-down module whereby said capacitor corrects the power factor of the associated A.C. power input.

12. The drive assembly according to claim 1 wherein the voltage of said output of said step-down module is not greater than 100 volts.

13. A drive assembly including a D C. electric motor and an integrated charger/controller for controlling said D.C. electric motor in a drive mode of operation and adapted to be connected to an electric power source for charging a battery in a charge mode of operation comprising:

(a) a power module having an output and an input adapted to be connected to an associated electric power source during a charge mode of operation wherein said power module provides a D.C. current to said output;

(b) a step-down module having an input connected to said power module and an output adapted to be connected to terminals of an associated battery, said step-down module including a transistor, a diode and an inductor, said transistor being connected in parallel with said diode and connected in series with said inductor said power module including said transistor of said step-down module, the voltage of said output of said step-down module being not greater than 100 volts;

(c) a control circuit including switch means having a multiplicity of switches, said control circuit having

(i) a drive mode of operation during which selected ones of said switches selectively effect the connection of the terminals of the associated battery to said input of said power module and selected ones of said switches selectively effect the connection of said output of said power module to said D.C. motor whereby said power module controls the said D.C. motor, and

(ii) a charge mode of operation during which said input of said power module is adapted to be connected to the associated electric power source, selected ones of said switches selectively effect the connection of said output of said power module to said input of said step-down module, and said output of said step-down module is adapted to be connected to the terminals of the associated battery whereby the associated battery is charged.

14. The drive assembly according to claim 13 wherein said power module is adapted to be connected to both a D.C. and an A.C. power source.

15. The drive assembly according to claim 13 wherein said power module is adapted to be connected to an A.C. power source to convert A.C. to D.C., and wherein said power module is a programmable pulse width modulated converter including power transistors and a parallel/series switching system, said parallel/series switching system connects said power transistors in series during said charge mode of operation whereby said power transistors rectify the associated A,C. current input to said D.C. current output of said power module and said parallel/series switching system connects said power transistors in parallel during said drive mode of operation whereby said power transistors control the associated D.C. motor.

16. The drive assembly according to claim 13 wherein said power module is adapted to be connected to an A.C. power source to convert A.C. to D.C., and said power module includes a transformer, diodes and transistors, whereby said transformer reduces the associated A.C. power source input voltage, said diodes rectify the A.C. current input to said D.C. current output of said power module, and said transistors control said D.C. motor.

17. In a method for charging a battery from an alternating current power source and for controlling a single phase D.C. motor, the steps comprising:

(a) providing a power module including an integrated power and step-down converter and switching means operable to effect switching between charging and motor drive modes;

(b) supplying alternating electric current from an electric power source to said power module;

(c) rectifying said alternating current in said power module to provide direct current;

(d) stepping down the voltage of said direct current in said module to provide an output of direct current at a lower voltage level;

(e) providing said direct current output directly to said battery to effect charging thereof;

(f) switching from the charging to the motor drive mode;

(g) supplying to said power module an unregulated direct current output from said battery; and

(h) controlling said unregulated direct current output from said battery in said power converter to produce a controlled direct current output to said single phase D.C. motor.

18. The method for charging a battery from an alternating current power source and for controlling a single phase D.C. motor in accordance with claim 17 wherein said step of rectifying said alternating current in said power module includes pulse width modulating said alternating current to provide said direct current.

19. The method for charging a battery from an alternating current power source and for controlling a single phase D.C. motor in accordance with claim 18 wherein said step of rectifying said alternating current in said power module includes connecting power transistors in series with a parallel/series switching system, and passing said alternating current through said power transistors to provide said direct current output.

20. The method for charging a battery from an alternating current power source and for controlling a single phase D.C. motor in accordance with claim 18 wherein said step of controlling unregulated D.C. current output in said power converter includes connecting power transistors in parallel with a parallel/series switching system converter, and passing said unregulated direct current output from said battery through said power transistors to control said single phase D.C. motor.