Modular vehicle power system

• US 7,952,225 B2
• Filed: 07/21/2008
• Issued: 05/31/2011
• Est. Priority Date: 07/20/2007
• Status: Expired due to Fees

• Current Assignee: Diversified Technologies Incorporated (Henkel AG & Co KGaA)
• Original Assignee: Diversified Technologies Incorporated (Henkel AG & Co KGaA)
• Inventors: Moak, David Bryant Jr., Reichard, Jeff A., Ables, Larry Monroe
• Primary Examiner(s): Fureman; Jared J
• Assistant Examiner(s): AMAYA, CARLOS DAVID
• Application Number:
  US12/176,480
• Publication Number:
  US 20090097292A1
• Time in Patent Office: 1,044 Days
• Field of Search: 307/9.1, 307/10.1, 307/82
• US Class Current: 307/10.1
• CPC Class Codes: B60L 13/04 Magnetic suspension or levitation for vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: H02J 7/1438 in combination with power supplies for loads other than batteries
• CPC Class Codes: H02M 7/493 the static converters being arranged for operation in parallel
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A modular vehicle power system for a vehicle, the modular vehicle power system obtaining DC power the vehicle and producing AC power and method therefore. A plurality of power modules, each of the plurality of power modules receiving the DC power from the vehicle and producing the AC power, wherein each of the plurality of power modules are independent and interchangeable.

Claims

1. A modular vehicle power system for a vehicle, said modular vehicle power system obtaining DC power said vehicle and producing AC power, comprising:

a plurality of power modules, each of said plurality of power modules receiving said DC power from said vehicle and producing said AC power, wherein each of said plurality of power modules are independent and interchangeable;

wherein said DC power has an input voltage and wherein each of said plurality of power modules utilize a variable switching frequency based upon said input voltage.

2. The modular vehicle power system as in claim 1 wherein said vehicle power system comprises at least three of each of said plurality of power modules, each one of said at least three of said plurality of power modules being associated with one of at least three phases of said AC power.

3. The modular vehicle power system as in claim 2 wherein each of said plurality of power modules comprises a plurality of power boards.

4. The modular vehicle power system as in claim 3 wherein each of said plurality of power boards of each of said plurality of power modules are coupled in series.

5. The modular vehicle power system as in claim 1 wherein said variable switching frequency increases as said input voltage increases.

6. The modular vehicle power system as in claim 5 wherein said variable switching frequency maintains an approximately constant voltage/frequency relationship.

7. The modular vehicle power system of claim 1 wherein said vehicle has a motor coupled with a throttle control and wherein said modular vehicle power system further comprises a speed controller operatively coupled with said throttle control of said vehicle and with each of said plurality of power modules to increase a speed of said motor of said vehicle in response an increased applied load from said modular vehicle power system.

8. A modular vehicle power system for a vehicle, said modular vehicle power system obtaining DC power said vehicle and producing AC power, comprising:

a plurality of power modules, each of said plurality of power modules receiving said DC power from said vehicle and producing said AC power, wherein each of said plurality of power modules are independent and interchangeable and wherein each of said plurality of power modules comprises;

a first power converter receiving said DC power from said vehicle, said first power converter utilizing a full MOSFET H-bridge producing a first AC power output;

a center-tapped power transformer receiving and rectifying said first AC power output to create a filtered DC voltage; and

a second power converter receiving said filtered DC signal, said second power converter utilizing a full MOSFET H-bridge to convert said filtered DC signal into a second AC power output.

9. The modular vehicle power system as in claim 8 wherein each of said plurality of power modules further comprises a local inductor output filter coupled to said second AC power output providing a first filtered AC output.

10. The modular vehicle power system of claim 8 wherein each of said plurality of power modules further comprises an input power clipping circuit operatively coupled to said DC power.

11. A modular vehicle power system for a vehicle, said modular vehicle power system obtaining DC power said vehicle and producing AC power, comprising:

a plurality of power modules, each of said plurality of power modules receiving said DC power from said vehicle and producing said AC power, wherein each of said plurality of power modules are independent and interchangeable;

wherein said vehicle power system comprises at least three of each of said plurality of power modules, each one of said at least three of said plurality of power modules being associated with one of at least three phases of said AC power; and

wherein each of said plurality of power modules comprises a plurality of power boards comprising;

a first power converter receiving said DC power from said vehicle, said first power converter utilizing a full MOSFET H-bridge producing a first AC power output;

a center-tapped power transformer receiving and rectifying said first AC power output to create a filtered DC voltage; and

a second power converter receiving said filtered DC signal, said second power converter utilizing a full MOSFET H-bridge to convert said filtered DC signal into a second AC power output.

12. The modular vehicle power system of claim 11 further comprising a general output filter coupled to said second AC power output of each of said plurality of power boards producing a combined AC output representing a power output for one of each of said at least three single phases of said AC power.

13. The modular vehicle power system of claim 11 wherein said second power converter operates at near 100% duty cycle.

14. A modular vehicle power system for a vehicle, said modular vehicle power system obtaining DC power said vehicle and producing AC power, comprising:

a plurality of power modules, each of said plurality of power modules receiving said DC power from said vehicle and producing said AC power, wherein each of said plurality of power modules are independent and interchangeable; and

a system chassis, wherein each of said plurality of power modules are individually, removably electrically, mechanically and thermally coupled to said system chassis;

wherein each of said plurality of power modules are substantially environmentally sealed from liquid immersion.

15. The modular vehicle power system of claim 14 wherein an individual seal between said system chassis and each of said plurality of power modules.

16. The modular vehicle power system of claim 15 wherein each of said plurality of power modules further comprises a heatsink, a power transformer and a machined transformer cup, said machined transformer cup and said individual seal coupling said power transformer to said heatsink providing thermal conductivity between said power transformer and said heatsink.

17. The method of claim 14 wherein an individual seal between said system chassis and each of said plurality of power modules.

18. The method of claim 17 wherein said substantially sealing step comprises thermally coupling a power transformer to a heatsink.

19. A method of providing AC power from a vehicle producing DC power, comprising the steps of:

providing a plurality of independent and interchangeable power modules, each of said plurality of power modules receiving said DC power from said vehicle and producing said AC power;

operating said plurality of independent and interchangeable power modules to provide multiple phase AC power; and

utilizing a variable switching frequency based upon said input voltage;

wherein each of said plurality independent and interchangeable power modules may operate for any one phase of said multiple phase AC power.

20. The method as in claim 19 wherein said providing step comprises providing at least three of each of said plurality of power modules, each one of said at least three of said plurality of power modules being associated with one of at least three phases of said AC power.

21. The method as in claim 20 wherein said providing step a plurality of power modules step further comprises providing a plurality of power boards for each of said plurality of power modules.

22. The method as in claim 21 wherein each of said plurality of power boards of each of said plurality of power modules are coupled in series.

23. The method as in claim 19 wherein said variable switching frequency increases/decreases as said input voltage increases/decreases.

24. The method as in claim 23 wherein said variable switching frequency maintains an approximately constant voltage/frequency relationship.

25. The method of claim 19 further comprising the step removably electrically, mechanically and thermally coupling each of said plurality of power modules to a system chassis.

26. The method of claim 25 further comprising the step of substantially sealing each of said plurality of power modules from liquid immersion.

27. The method of claim 19 further comprising the step of increasing a throttle of said vehicle responsive to an increased load for said AC power.