Method and system for controllably transferring energy from a high voltage bus to a low voltage bus in a hybrid electric vehicle

• US 7,199,551 B2
• Filed: 09/26/2003
• Issued: 04/03/2007
• Est. Priority Date: 09/26/2003
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Mack, David J., Anthony, Joseph W., Ochocinski, Christopher A., Gokhale, Renuka V., Gauthier, Greg E.
• Primary Examiner(s): Tso; Edward H.
• Application Number:
  US10/605,388
• Publication Number:
  US 20050068003A1
• Time in Patent Office: 1,285 Days
• Field of Search: 320/103, 320/104, 320/118, 320/127, 320/140
• US Class Current: 320/104
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• 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 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/31 for starting of fuel cells
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60Y 2400/112 Batteries
• CPC Class Codes: H02J 7/1423 with multiple batteries
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A method and system for controllably transferring energy from a high voltage bus to a low voltage bus in a hybrid electric vehicle. A vehicle system controller controls a DC/DC converter coupled between the high voltage bus and the low voltage bus to control the transfer of energy therebetween.

Claims

1. A method for operating a hybrid electric vehicle (HEV) having a low voltage bus, a high voltage bus, and a DC convertor electrically coupling the low and high voltage busses, the method comprising:

controllably transferring energy from the high voltage bus to the low voltage bus during prestart of the high voltage bus by controlling energy flow through the DC/DC converter.

2. The method of claim 1 further comprising determining a battery energy level of a high voltage battery coupled to the high voltage bus, the high voltage battery for storing electric energy for use in precharging the high voltage bus, controllably transferring energy to the low voltage bus from the energy provided to the high voltage bus by the high voltage battery if the battery energy level is greater than a predefined energy level.

3. The method of claim 2 further comprising determining a battery state of charge for the high voltage battery, the battery energy equaling the battery state of charge.

4. The method of claim 3 further comprising determining a battery power discharge limit for the high voltage battery, the battery energy equaling the battery power discharge limit.

5. The method of claim 2 further comprising determining whether the high voltage battery energy is sufficient for powering an electric starter used for starting the vehicle, transferring energy to the low voltage bus only if the high voltage battery energy is sufficient for power the electric starter.

6. The method of claim 5 further comprising continuously monitoring the battery energy, preventing further transfer of energy to the low voltage bus if the battery energy drops below a predefined energy threshold, the predefined threshold being greater than the energy needed for starting the electric starter.

7. The method of claim 2 further comprising determining precharging by sensing an ignition key turned to a run position, determining prestart by closing opened contactors coupled between the high voltage battery and the high voltage bus once the high voltage bus is charged, and transferring energy to the low voltage bus only if the contactors are closed.

8. The method of claim 1 further comprising determining a battery voltage of a low voltage battery coupled to the low voltage bus, controllably transferring energy to the low voltage bus based on the battery voltage of the low voltage battery.

9. The method of claim 8 further comprising limiting energy transfer to the low voltage bus if the battery voltage of the low voltage battery is greater than a predefined voltage.

21. The method of claim 1 further comprising performing the prestart after precharging the high voltage bus, the precharging characterized discharging a high voltage energy storage source to the high voltage bus prior to closing contactors used to electrically connect the high voltage energy storage source to an electrically operable drive element used to drive the vehicle, wherein the prestart and transferring energy from the high voltage bus to the low voltage bus occurs only after precharing is completed.

22. The method of claim 21 further comprising operating a precharging device to precharge the high voltage bus prior to closing the contactors.

10. A vehicle system controller for operating a hybrid electric vehicle (HEV) having a low voltage bus for providing power to accessory loads and a high voltage bus electrically coupled to the low voltage bus by a DC/DC converter, the high voltage bus providing power for electric driving of the vehicle, the controller comprising:

means for controllably transferring energy from the high voltage bus to the low voltage bus during prestart of the high voltage bus by controlling energy flow through the DC/DC converter.

11. The controller of claim 10 wherein the controller further comprises means for determining a battery energy level of a high voltage battery coupled to the high voltage bus and controllably transferring energy to the low voltage bus from the energy provided to the high voltage bus by the high voltage battery if the battery energy level is greater than a predefined energy level.

12. The controller of claim 11 wherein the controller further comprises means for determining a battery state of charge for the high voltage battery, the battery energy level equaling the battery state of charge.

13. The controller of claim 11 wherein the controller further comprises means for determining a battery power discharge limit for the high voltage battery, the battery energy level equaling the battery power discharge limit.

14. The controller of claim 11 wherein the controller further comprises means for determining whether the battery energy is sufficient for powering an electric starter used for starting the vehicle and transferring energy to the low voltage bus only if the battery energy level is sufficient to power a electric starter.

15. The controller of claim 14 wherein the controller further comprises means for continuously monitoring the battery energy and preventing further transfer of energy to the low voltage bus if the battery energy drops below a predefined energy threshold.

16. The controller of claim 11 wherein the controller further comprises means for determining prestart by sensing closing of opened contactors coupled between the high voltage battery and the high voltage bus once the high voltage bus is charged and transferring energy to the low voltage bus only if the contactors are closed.

17. The controller of claim 10 wherein the controller further comprises means for determining a battery voltage of a low voltage battery coupled to the low voltage bus and controllably transferring energy to the low voltage bus based on the battery voltage of the low voltage battery.

18. The controller of claim 17 wherein the controller further comprises means for limiting energy transfer to the low voltage bus if the battery voltage of the low voltage battery is greater than a predefined voltage.

19. A hybrid electric vehicle system, the system comprising:

an internal combustion engine;

a generator/motor for electrically starting the internal combustion engine;

a high voltage battery for storing high voltage energy;

a high voltage bus coupled between the generator/motor and the high voltage battery;

contactors coupled between the high voltage battery and the high voltage bus to electrically isolate the high voltage battery from the high voltage bus when opened;

a precharging device for precharging the high voltage bus prior to closing of the opened contactors;

a low voltage battery for storing low voltage energy and powering accessories;

a low voltage bus coupled between the battery and the accessories;

a DC/DC converter coupled between the high voltage bus and the low voltage bus, the DC/DC converter being isolated from the high voltage battery when the contactors are opened; and

a vehicle system controller, the vehicle system controller including instructions for controllably transferring energy from the high voltage bus to the low voltage bus during prestart of the high voltage bus by controlling energy flow through the DC/DC converter.

20. The system of claim 19 wherein the vehicle system controller further comprises instructions for transferring energy to the low voltage bus only if a high voltage battery energy is sufficient for powering the generator/motor for starting the engine.