System, method and apparatus for connecting electrical sources in series under full load

• US 6,646,360 B2
• Filed: 08/01/2002
• Issued: 11/11/2003
• Est. Priority Date: 12/20/1999
• Status: Expired due to Term

• Current Assignee: Siemens Industry Incorporated (Siemens AG)
• Original Assignee: Siemens Energy & Automation
• Inventors: Brown, Gerald M.
• Primary Examiner(s): Toatley, Jr., Gregory J.
• Assistant Examiner(s): RIOS CUEVAS, ROBERTO JOSE
• Application Number:
  US10/210,276
• Publication Number:
  US 20030025399A1
• Time in Patent Office: 467 Days
• Field of Search: 307/9.1, 307/10.1, 307/44, 307/50, 307/69, 307/70, 307/71, 307/76, 307/77, 307/78, 307/43, 191/2, 191/3, 191/4, 180/65.1, 180/65.3, 180/65.4
• US Class Current: 307/43
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• 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

Abstract

A circuit connects a low-voltage high-current DC power source (P_L) in series with a high-voltage low-current DC source (P_D). The series connection is made under full power by using the second source P_L to commutate the load current and allow the first source P_D to be reconfigured from series to parallel operation, doubling its current rating.

Claims

1. A system that seamlessly places an additional power source (P₁) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P₁) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said first source (P_D) is coupled to at least two series-connected circuit elements that each supply a portion of said power to said load;

wherein said controller couples said second source (P_L) in parallel with at least one of said circuit elements and then uncouples at least one of said circuit elements from said second source (P_L) thereby seamlessly placing the at least one of said circuit elements of the at least two series-connected circuit elements of said first source in series with said second source (P_L).

2. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load.

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load.

3. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load,

wherein said shared circuit element is a first rectifier and said circuit element is a second rectifier.

4. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load,

wherein said shared circuit element is a first rectifier and said circuit element is a second rectifier, and

wherein said first source is a dual-winding source, and wherein said first rectifier is coupled to a first winding of said first source and said second rectifier is coupled to a second winding of said first source.

5. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load,

wherein said shared circuit element is a first rectifier and said circuit element is a second rectifier,

further comprising a switch that selectively uncouples a positive output terminal of said first rectifier from a negative output terminal of said second rectifier, thereby breaking the series connection of said circuit elements of said first source.

6. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load,

wherein said shared circuit element is a first rectifier and said circuit element is a second rectifier,

further comprising a switch that selectively uncouples a positive output terminal of said first rectifier from a negative output terminal of said second rectifier, thereby breaking the series connection of said circuit elements of said first source,

further comprising a second switch for selectively uncoupling a negative output terminal of said first rectifier from the negative input terminal of load and coupling said negative output terminal to a negative output terminal of a said remaining circuit element of said first source, thereby preparing for configuring said first rectifier in said parallel configuration.

7. A system that seamlessly places an additional power source (P_L) in series with a first source (P_D) while said source P_D supplies a load with power when additional power is required by said load, said system comprising:

a first source (P_D) for supplying said load with power;

a second source (P_L) for supplying said load with additional power; and

a controller that electrically couples said second source seamlessly in series with said first source (P_D) such that, while said first source (P_D) supplies power to said load, said second source (P_L) is seamlessly placed in series with said first source (P_D) to significantly increase power to said load,

wherein said controller switches between an internal series configuration of said circuit elements of said first source which provides power from said first source to the load and a parallel configuration of said circuit elements which provides power from said first source to the load in conjunction with said second source,

wherein said series configuration configures a circuit element that channels power from said first source to said load in series with a shared circuit element, which is shared between said first source and said second source, that channels power from said first source to said load, and wherein said parallel configuration configures said circuit element in parallel with said shared element, which channels power from said first source in conjunction with said second source to said load,

wherein said shared circuit element is a first rectifier and said circuit element is a second rectifier,

further comprising a switch that selectively uncouples a positive output terminal of said first rectifier from a negative output terminal of said second rectifier, thereby breaking the series connection of said circuit elements of said first source,

further comprising a second switch for selectively uncoupling a negative output terminal of said first rectifier from the negative input terminal of load and coupling said negative output terminal to a negative output terminal of a said remaining circuit element of said first source, thereby preparing for configuring said first rectifier in said parallel configuration,

further comprising a third switch for selectively coupling said positive output terminal of said first rectifier to a positive output terminal of said second rectifier, thereby configuring said first rectifier in said parallel configuration.

8. A method of providing additional power to a load, where the load is connected to a first rectifier and a second rectifier, the first and second rectifiers being coupled to an engine by an alternator, the method comprising:

adjusting excitation of the alternator such that outputs of the first and second rectifiers approximate an external line voltage (U_L) of an external source (P_L);

connecting the external source (P_L) in parallel with an output of the first rectifier;

opening a series connection between the first and second rectifiers;

disconnecting a negative output of the first rectifier and connecting the negative output of the first rectifier to a negative output of the second rectifier;

connecting the first rectifier in parallel with the second rectifier by connecting a positive output of the first rectifier to a positive output of the second rectifier; and

increasing power to the load by increasing the load current.

9. The method of claim 8, wherein increasing power to the load by increasing the load current includes receiving additional power from the external source (P_L).

10. The method of claim 8, wherein opening a series connection between the first and second rectifiers includes opening a switch.

11. The method of claim 8, further comprising measuring the external line voltage (U_L).

12. The method of claim 8, wherein connecting the external source (P_L) in parallel with an output of the first rectifier includes closing a line contactor.

13. The method of claim 8, wherein increasing power to the load by increasing the load current includes sharing current between the first and second rectifiers.

14. A system in which a low-voltage, high-current DC power source (P_L) is connected in series with a high-voltage, low-current DC power source (P_D) when additional power is required by a load, the system comprising:

a diesel mode in which first and second rectifiers coupling an alternator, to provide the high-voltage, low-current DC power source (P_D), are connected in series to supply a diesel rated current and rated voltage to the load; and

a diesel boost mode in which the first and second rectifiers are connected in parallel to supply twice the diesel rated current at half the rated voltage, wherein the low-voltage, high-current DC power source (P_L) is connected in parallel with the first rectifier of the two rectifiers in the diesel mode such that the first rectifier can be disconnected and reconnected with the second rectifier of the two rectifiers in the diesel boost mode, wherein power to the load can be increased to maximum rated load current after the system seamlessly moves from diesel mode to diesel boost mode.

15. The system of claim 14, further comprising means for connecting rectifier circuits in series.

16. The system of claim 15, further comprising means for measuring an external line voltage and adjusting alternator excitation such that rectified outputs of alternator windings are close to the external line voltage.

17. The system of claim 16, further comprising means for closing a line contactor to connect an external power source (P_L) in parallel with an output of a first rectifier.

18. The system of claim 17, further comprising means for reducing the alternator excitation to lower the outputs of the rectifiers.

19. The system of claim 17, further comprising means for opening a switch to open a series connection between the rectifiers at zero current.

20. The system of claim 19, further comprising means for disconnecting a negative output of the first rectifier and connecting a positive output of the first rectifier to the positive output of the second rectifier.