Embedded wireless communications for electronic control unit having multiple ground references

• US 8,203,232 B2
• Filed: 12/10/2009
• Issued: 06/19/2012
• Est. Priority Date: 12/10/2009
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Pino, Rafael Jimenez, Aceña, Miguel Angel
• Primary Examiner(s): DeBeradinis, Robert L.
• Application Number:
  US12/635,001
• Publication Number:
  US 20110140512A1
• Time in Patent Office: 922 Days
• Field of Search: 307/10.1
• US Class Current: 307/10.1
• CPC Class Codes: B60L 3/0023 Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• 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 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

Abstract

A system configured to facilitate wireless communications between different ground planes is provided. The system may rely on bi-directional communications between galvanically isolated components to support any number of operations, including but not limited operations associated with supporting wireless message communications between three or more isolated ground planes, such as but not limited to supporting communications between three or more ground planes included within an onboard vehicle charger.

Claims

1. A power electronics device for use onboard a vehicle having three or more isolated power systems, the power electronics device comprising:

a converter for managing energy flow between a first one and a second one of the isolated power systems, the converter having a first stage on a first ground plane and a second stage on a second ground plane, the first and second ground planes being galvanically isolated from each other and including a plurality of switching power elements to facilitate managing energy flow between the first and second isolated power systems; and

an electronic control system (ECS) configured to control the switching power elements according to messages received from each of the isolated power systems, the ECS using wireless radio frequency communications to communicate the messages between each of the isolated power systems.

2. The device of claim 1 further comprising a first transceiver on the first ground plane, a second transceiver on the second ground plane, and a third transceiver on a third ground plane, the third ground plane used on by a data network of a third isolated power system, the third isolated power system being galvanically isolated from each of the first and second ground planes, wherein the ECS uses the first transceiver, the second transceiver and the third transceiver to communicate the messages between each of the isolated power systems.

3. The device of claim 2 wherein each message is transmitted from one of the first transceiver, the second transceiver and the third transceiver and received by each of the other transceivers.

4. The device of claim 2 wherein each transceiver is configured to support bi-directional communications with each other.

5. An onboard high voltage charger for use in a vehicle having a mains power system, a high voltage (HV) power system, and a low voltage (LV) power system, each of the mains, HV, and LV power systems having electrically isolated ground planes, respectively referred to as a mains ground plane, an HV ground plane, and an LV ground plane, the charger comprising:

a transformer for transferring energy from the main power system to the HV power system through an electrical coupling between a primary coil of a primary stage and a secondary coil of a secondary stage, the primary coil connecting to the mains power system and the secondary coil connecting to the HV power system, wherein energy flow to the primary coil is controlled with a first plurality of power elements and energy flow from the secondary coil is controlled with a second plurality of power elements; and

an electronic control unit (ECU) configured to control the first and second plurality of power elements, the ECU having a mains wireless interface, an HV wireless interface, and an LV wireless interface respectively connected to the mains, HV, and LV ground planes, the ECU relying on wireless exchange of messages between each of the wireless interfaces to control operations of the first plurality of power elements and the second plurality of power elements, wherein the mains wireless interface, the HV wireless interface and the LV wireless interface are galvanically isolated from each other

wherein the wireless interfaces wirelessly exchange messages according to a redundant, data communication protocol that requires each of a transmitting one of the wireless interfaces to broadcast the message to each non-transmitting wireless interface.

6. The charger of claim 5 wherein the data communication protocol only permits one of the wireless interfaces to transmit data at the same time.

7. The charger of claim 5 wherein each of the non-transmitting wireless interfaces transmits an acknowledgement to the transmitting one of the wireless interfaces after receipt of the transmitted data.

8. The charger of claim 7 wherein one of the wireless interfaces receiving the acknowledgements transmits a warning message to indicate failure of one of the acknowledgment transmitting mains wireless interface, HV wireless interface and LV wireless interface in the event only one acknowledgment is received.

9. The charger of claim 5 wherein each message includes an identification of the wireless interface intended to receive the message.

10. The charger of claim 5 wherein each of the mains wireless interface, the HV wireless interface and the LV wireless interface includes a microcontroller and an RF data modem, each microcontroller configured to process messages carried over networks of the respective power systems.

11. The charger of claim 5 further comprising one or more printed circuit boards (PCBs) connected to each of the transformer, first plurality of power elements and second plurality of power elements, mains wireless interface, HV wireless interface and LV wireless interface and ECU.

12. The charger of claim 11 further comprising a housing configured to protect each PCB, transformer, power elements, wireless interfaces, and ECU within an enclosure.

13. The charger of claim 12 wherein the housing prevents wireless signals transmitted between the mains wireless interface, the HV wireless interface and the LV wireless interface from emitting beyond the enclosure.

14. The charger of claim 11 wherein a wireless communication range of each of the mains wireless interface, the HV wireless interface and the LV wireless interface is not more than twice a length of the PCB.

15. An onboard high voltage charger for use in a vehicle having a mains power system, a high voltage (HV) power system, and a data network, each of the mains power system, HV power system, and the data network having electrically isolated ground planes, respectively referred to as a mains ground plane, an HV ground plane, and a data network ground plane, the charger comprising:

a transformer for transferring energy from the mains power system to the HV power system through an electrical coupling between a primary coil of a primary stage and a secondary coil of a secondary stage, the primary coil connecting to the mains power system and the secondary coil connecting the HV power system, wherein energy flow to the primary coil is controlled with a first plurality of power elements and energy flow from the secondary coil is controlled with a second plurality of power elements; and

an electronic control unit (ECU) configured to control the first and second plurality of power elements, the ECU having a mains wireless interface, an HV wireless interface, and a data network wireless interface respectively connected to the mains, HV, and data network ground planes, the ECU controlling the first plurality of power elements and the second plurality of power elements based in part on messages transmitted from the data network wireless interface to at least one of the mains wireless interface and the HV wireless interface, wherein at least a portion of the messages transmitted from the data network wireless interface originate from one or more data collecting elements connected to the data network

wherein the data network wireless interface transmits each message to both of the mains and HV wireless interfaces and each of the mains and HV wireless interface generate an acknowledgment message upon receipt thereof.

16. The charger of claim 15 wherein the mains wireless interface, the HV wireless interface and the LV wireless interface are galvanically isolated from each other.

17. The charger of claim 15 wherein each of the one or more data collecting elements is galvanically isolated from each of the mains ground plane and the HV ground plane.

18. The charger of claim 15 wherein the ECU transmits a warning message to indicate failure in the event only one acknowledgment is received by the data network wireless interface and wherein the ECU relies on backup non-wireless communications to execute communications previously executed by the failed one of the mains wireless interface, the HV wireless interface and the LV wireless interface.