Leakage current reduction in combined motor drive and energy storage recharge system

• US 8,242,739 B2
• Filed: 07/20/2010
• Issued: 08/14/2012
• Est. Priority Date: 07/20/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Krauer, Jean-Pierre, Kalayjian, Nick
• Primary Examiner(s): Fantu, Yalkew
• Application Number:
  US12/840,045
• Publication Number:
  US 20120019194A1
• Time in Patent Office: 756 Days
• Field of Search: 320/107
• US Class Current: 320/107
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• 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: 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 charging system and method that accommodates and reduces potential residual or leakage current when electrical grounds of a charger and an energy storage system are equalized at the moment of initiating charging. The charging system using an alternating current (AC) line voltage for conductive charging of an energy storage system (ESS) coupled to a polyphase motor drive circuit communicated to a polyphase motor, and converting the line voltage to a charging voltage communicated to the energy storage system using a set of the plurality of driver stages.

Claims

1. A charging system using an alternating current (AC) line voltage for conductive charging that reduces potential residual or leakage current, and an energy storage system (ESS) coupled to a polyphase motor drive circuit communicated to a polyphase motor, the polyphase motor drive circuit including a plurality M of driver stages, one driver stage for each phase of the polyphase motor with each driver stage coupled across the energy storage system, the system comprising:

a converter, coupled to the energy storage system and including a number N number of the plurality of driver stages, with N less than M, to convert the line voltage to a charging voltage responsive to a first plurality of drive signals, wherein said charging voltage is communicated to the energy storage system;

a switching assembly, coupled between the plurality of driver stages and the line input voltage, controlling communication of the line voltage to the plurality of driver stages, said switching assembly including an on mode that couples the line voltage to the plurality of driver stages and an off mode that decouples the line voltage from the plurality of driver stages;

a sensing circuit, coupled to the line voltage and to the energy storage system, measuring an ESS common mode voltage of the energy storage system to a voltage reference and measuring a line common mode voltage of the line voltage to said voltage reference when said switching assembly is in said off mode;

a common mode voltage driver, coupled to the energy storage system and to at least one driver stage of said plurality of driver stages, said at least one driver stage not including one of said N number of driver stages and responsive to a second set of driver signals to match said ESS common mode voltage with said line common mode voltage when said switching assembly is in said off mode; and

a controller, coupled to said plurality of driver stages and responsive to a voltage comparison between said ESS common mode voltage and said line common mode voltage, to provide said second set of driver signals to decrease a difference between said ESS common mode voltage and said line common mode voltage to be within a predetermined value, said controller transitioning said switching assembly from said off mode to said on mode when said difference between said ESS common mode voltage and said line common mode voltage is within said predetermined value, and said controller providing said first set of plurality of drive signals when said switching assembly is in said on mode.

2. The charging system of claim 1 wherein said common mode voltage driver includes a resistance coupling said at least one driver stage to said voltage reference.

3. The charging system of claim 1 further comprising a current sensor, coupled to said controller and to an input of said converter receiving the line voltage, to measure a ground residual-current device (RCD) current flow wherein said controller provides said first set of driver signals to regulate said ground RCD current flow to be less than a second predetermined value.

4. A charging method using an alternating current (AC) line voltage for conductive charging that reduces potential residual or leakage current, and an energy storage system (ESS) coupled to a polyphase motor drive circuit communicated to a polyphase motor, the polyphase motor drive circuit including a plurality M of driver stages, one driver stage for each phase of the polyphase motor with each driver stage coupled across the energy storage system, the method comprising the steps of:

(a) coupling a first connector providing the line voltage to a second connector coupled to the plurality of driver stages;

(b) interrupting selectably the line voltage from communication with the plurality of driver stages;

(c) measuring both an ESS common mode voltage of the energy storage system with respect to a voltage reference and a line common mode voltage of the line voltage with respect to said voltage reference while the line voltage communication to the plurality of driver stages is interrupted;

(d) operating a particular one of the driver stages to power a common mode voltage driver to align said ESS common mode voltage with said line common mode voltage while the line voltage communication to the plurality of driver stages is interrupted; and

thereafter (e) suspending said interrupting step (b) when a difference between aid ESS common mode voltage and said line common mode voltage is less than a first predetermined value, said suspending step (e) communicating the line voltage to the plurality of driver stages; and

thereafter (f) converting the line voltage to a charging voltage communicated to the energy storage system using a set of the plurality of driver stages not including said particular one driver stage.

5. The charging method of claim 4 further comprising the step of:

(g) measuring, during converting step (f), ground RCD current flow through said connectors;

(h) regulating said ground RCD current flow to be less than a second predetermined value using said set of driver stages.