HEV charger/generator unit

• US 6,724,100 B1
• Filed: 09/08/2000
• Issued: 04/20/2004
• Est. Priority Date: 09/08/2000
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Gabriel, David
• Primary Examiner(s): DEBERADINIS, ROBERT L
• Application Number:
  US09/659,018
• Time in Patent Office: 1,320 Days
• Field of Search: 307/9.1, 180/65.1, 180/65.2, 180/65.3
• US Class Current: 307/9.1
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/006 to power outlets
• CPC Class Codes: B60L 15/025 using field orientation; Vector control; Direct Torque Control [DTC]
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/54 Windings for different functions
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle
• 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
• 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
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/906 : Motor or generator

Abstract

The present invention provides an apparatus, system, and method of utilizing a Home Power Unit (“HPU”) which functions as a battery charger for a Hybrid Electric Vehicle (“HEV”) or as a generator, utilizing the HEV'"'"'s electrical power to operate external electrical devices. In its simplest form, the HPU comprises a Transformer, inverter means, rectifier means, a control unit, connection means to the HEV and external electrical loads or sources and switching means to change operation between charger and generator function. Alternative embodiments of the present invention utilize the HEV'"'"'s existing components thereby avoiding component redundancy within the HPU. Specifically, in the first alternative embodiment, the inverter means are utilized within the vehicle, therefore, requiring only filter and transformer to be added to the vehicle. In the second alternative embodiment, the vehicle'"'"'s DC-to-DC Converter is utilized as opposed to implementing a transformer. Therefore, only an inverter and filter are added to the system.

Claims

1. A motor vehicle electrical power system for powering an electrical load external to the vehicle, comprising:

an internal combustion engine;

a battery;

an electric generator coupled to said internal combustion engine for generating AC electrical power when said internal combustion engine is running;

a generator inverter disposed between said electric generator and said battery for converting the AC electrical power generated by said electric generator to DC electrical power for storage in said battery;

an electric traction motor coupled to said battery;

a traction inverter coupled to said battery for converting the stored DC electrical power to an AC power input for said electric traction motor;

a switching device disposed between said traction inverter and said electric traction motor for selectively diverting the AC electrical power input for application to the external electrical load;

means for powering the external electrical load only if a safety condition is satisfied; and

means for prohibiting movement of the vehicle when powering the external electrical load.

2. The system according to claim 1, wherein said switching device comprises a contactor.

3. The system according to claim 1, further comprising:

a filter coupled to said switching device for minimizing noise in the diverted AC power input; and

a transformer coupled between said filter and the external electrical load.

4. The system according to claim 1, further comprising:

a DC-to-DC converter coupled between said first electric machine and said first inverter for generating lower voltage DC electrical power from the DC electrical power produced by said first inverter;

an inverter coupled to said DC-to-DC inverter for converting the lower voltage DC electrical power to an AC power output for application to the external electrical load.

5. The system according to claim 4, further comprising a second filter for minimizing noise in the AC power output.

6. The system according to claim 4, wherein:

said DC-to-DC converter is a two-way DC-to-DC converter;

said inverter comprises a rectifier, and

said system is operable in a charger mode.

7. The system according to claim 6, further comprising means for selecting operation of said system in a generator mode versus the charger mode.

8. The system according to claim 1, wherein said control means inhibits operation of said system based on one or more of a gear selector position, door open/shut condition and parking brake condition.

9. A motor vehicle electrical power generating system for powering an electrical load external to the vehicle, comprising:

an internal combustion engine;

a battery;

an electric generator coupled to said internal combustion engine for generating AC electrical power when said internal combustion engine is running;

a generator inverter disposed between said electric generator and said battery for converting the AC electrical power generated by said electric generator to DC electrical power;

a DC-to-DC converter coupled between said electric generator and said generator inverter for generating lower voltage DC electrical power from the DC electrical power produced by said generator inverter;

an inverter coupled to said DC-to-DC converter for converting the lower voltage DC electrical power to an AC power output to power the external electrical load;

means for powering the external electrical load only if a safety condition is satisfied; and

means for prohibiting movement of the vehicle when powering the external electrical load.

10. The system according to claim 9, further comprising a second filter for minimizing noise in the AC power output.

11. The system according to claim 9, wherein:

said DC-to-DC converter is a two-way DC-to-DC converter;

said inverter comprises a rectifier; and

said system is operable in a charger mode.

12. The system according to claim 11, further comprising means for selecting operation of said system in a generator mode versus the charger mode.

13. The system according to claim 9, wherein said control means inhibits operation of said system based on one or more of a gear selector position, door open/shut condition and parking brake condition.

14. A method for operating a hybrid electric vehicle having a battery, inverter and at least one electric motor, the method comprising:

applying DC electrical power stored in the battery to the inverter to generate AC electrical power for the motor;

diverting the AC electrical power to an external load so as to operate the vehicle in a generator mode;

operating the vehicle in the generator mode only if a safety condition is satisfied; and

prohibiting movement of the vehicle when operating the vehicle in the generator mode.

15. The method according to claim 14, wherein said operating step comprises the step of inhibiting generator mode operation based on a gear selector position of the vehicle.

16. The method according to claim 14, wherein said operating step comprises the step of inhibiting generator mode operation based on a door open/shut condition of the vehicle.

17. The method according to claim 14, wherein said operating step comprises the step of inhibiting generator mode operation based on a parking brake condition of the vehicle.

18. A method for operating a hybrid electric vehicle having a battery, DC-to-DC converter, at least one electric generator coupled to an internal combustion engine, and a generator inverter the method comprising:

operating the internal combustion engine to generate AC electrical power from the generator;

applying the generated AC electrical power to the generator inverter in order to generate DC electrical power;

applying the DC electrical power to the DC-to-DC converter to generate a lower voltage DC electrical power;

inverting the lower voltage DC electrical power to a generate an AC power output for an external load, thereby operating the vehicle in a generator mode;

operating the vehicle in the generator mode only if a safety condition is satisfied; and

prohibiting movement of the vehicle when operating the vehicle in the generator mode.

19. The method according to claim 18, wherein said operating step comprises the step of inhibiting generator mode operation based on a gear selector position of the vehicle.

20. The method according to claim 18, wherein said operating step comprises the step of inhibiting generator mode operation based on a door open/shut condition of the vehicle.

21. The method according to claim 18, wherein said operating step comprises the step of inhibiting generator mode operation based on a parking brake condition of the vehicle.

22. The method according to claim 18, wherein the DC-to-DC converter is bidirectional and wherein the method further comprises the step of operating the vehicle in a charging mode.