Energy management system to improve efficiency of electric and hybrid drive trains

• US 8,120,290 B2
• Filed: 10/13/2008
• Issued: 02/21/2012
• Est. Priority Date: 10/13/2008
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: King, Robert Dean
• Primary Examiner(s): Ip, Paul
• Application Number:
  US12/250,182
• Publication Number:
  US 20100090626A1
• Time in Patent Office: 1,226 Days
• Field of Search: 318/139, 318/430, 318/437, 318/109, 318/440, 318/442, 180/65.1, 180/65.3
• US Class Current: 318/139
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 7/16 for vehicles comprising converters between the power source and the motor
• CPC Class Codes: H02P 2201/09 Boost converter, i.e. DC-DC step up converter increasing the voltage between the supply and the inverter driving the motor general aspects of plural converters in cascade H02M
• 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 propulsion system is provided that includes an electric drive, a first energy storage system electrically coupled to the electric drive through a direct current (DC) link, and a second energy storage system electrically coupled to the electric drive. The propulsion system further includes a multi-channel bi-directional boost converter coupled to the first energy storage system and to the second energy storage system such that the second energy storage system is decouplable from the DC link, wherein the second energy storage system comprises at least one battery coupled in series with at least one ultracapacitor.

Claims

1. A propulsion system comprising:

an electric drive;

a first energy storage system electrically coupled to the electric drive through a direct current (DC) link;

a second energy storage system electrically coupled to the electric drive; and

a multi-channel bi-directional boost converter coupled to the first energy storage system and to the second energy storage system such that the second energy storage system is decouplable from the DC link;

wherein the second energy storage system comprises at least one power battery coupled in series with at least one ultracapacitor, the second energy storage system further comprises at least one energy battery and a unidirectional conducting apparatus configured so the multi-channel bi-directional boost converter extracts power and energy from the at least one power battery and a lower power level from the at least one energy battery using two channels.

2. The propulsion system of claim 1, wherein the electric drive is one of an alternating current (AC) traction drive or a direct current (DC) traction drive.

3. The propulsion system of claim 1, wherein the first energy storage system comprises at least one of a power battery and an ultracapacitor, and the first energy storage system is coupled to the multi-channel bi-directional boost converter through the DC link.

4. The propulsion system of claim 3, wherein the first energy storage system comprises the power battery and is configured to provide a regenerative energy to the at least one ultracapacitor of the second energy storage system.

5. The propulsion system of claim 1, wherein the at least one ultracapacitor of the second energy storage system is configured to capture energy during regenerative braking events associated with vehicle deceleration.

6. The propulsion system of claim 5, wherein the multi-channel bi-directional boost converter is configured to control an amount of energy transferred to the at least one ultracapacitor of the second energy storage system during the regenerative braking events as a function of at least one of vehicle speed, state-of-charge of the at least one ultracapacitor, state-of-charge of the battery, electric drive torque demand and electric drive speed.

7. The propulsion system of claim 1, wherein the second energy storage system further comprises a pre-charge circuit configured to at least partially charge the at least one ultracapacitor.

8. The propulsion system of claim 1, further comprising an auxiliary power unit coupled to the second energy storage system.

9. The propulsion system of claim 8, wherein the auxiliary power unit is a heat engine.

10. The propulsion system of claim 8, wherein the auxiliary power unit comprises both a heat engine and a plug-in electrical interface.

11. The propulsion system of claim 8, wherein the auxiliary power unit comprises a plug-in electrical interface.

12. A method of assembling a control system comprising:

coupling a first energy storage system to an electric drive through a direct current (DC) link;

connecting an ultracapacitor in series with a power battery, and at least one energy battery and a unidirectional conducting apparatus to form a second energy storage system; and

coupling a multi-channel bi-directional boost converter to each of the first energy storage system and second energy storage system such that the first energy storage system is decoupled from the second energy storage system, and wherein the multi-channel bi-directional boost converter is further coupled to the electric drive through the DC link, further wherein the multi-channel bi-directional boost converter extracts power and energy from the power battery and a lower power level from the at least one energy battery using two channels.

13. The method of claim 12, comprising coupling a pre-charge circuit to the ultracapacitor to at least partially recharge the ultracapacitor.

14. The method of claim 12, comprising coupling another ultracapacitor to the second energy storage system.

15. The method of claim 12, comprising dynamically controlling an input and an output voltage of the ultracapacitor coupled in series with the power battery through the multi-channel bi-directional boost converter, and controlling an amount of energy transferred to the ultracapacitor coupled in series with the power battery during a regenerative breaking event, wherein the amount of energy transferred is a function of at least one of vehicle speed, state-of-charge of the ultracapacitor, state-of-charge of the battery, electric drive torque demand and electric drive speed.

16. An energy storage arrangement for an electrically powered system, the arrangement comprising:

at least one ultracapacitor coupled in series with at least one power battery;

at least one energy battery and a unidirectional conducting apparatus; and

a multi-channel bi-directional boost converter coupled to the at least one ultracapacitor and the at least one power battery, wherein the multi-channel bi-directional boost converter is configured to dynamically control an input and an output voltage from the at least one ultracapacitor and the at least one power battery, further wherein the at least one energy battery and the unidirectional conducting apparatus configured so the multi-channel bi-directional boost converter extracts power and energy from the at least one power battery and a lower power level from the at least one energy battery using two channels.

17. The energy storage arrangement of claim 16, wherein the multi-channel bi-directional boost converter is further coupled to an alternating current (AC) traction drive through a direct current (DC) link.

18. The energy storage arrangement of claim 16, wherein the multi-channel bi-directional boost converter is configured to control an amount of energy captured by the at least one ultracapacitor during a regenerative braking event.

19. The energy storage arrangement of claim 16, wherein stored energy from both the at least one ultracapacitor and the at least one power battery is provided through the multi-channel bi-directional boost converter during high speed and high power acceleration of a vehicle powered by the electrically powered system.

20. The energy storage arrangement of claim 16, further comprising a heat engine coupled to the at least one ultracapacitor and the at least one power battery to supply auxiliary power thereto.

21. The energy storage arrangement of claim 16, further comprising a heat engine and a plug-in electrical interface both coupled to the at least one ultracapacitor and the at least one power battery to provide auxiliary power thereto.