Control system for hybrid vehicles with reconfigurable multi-function power converter

• US 8,417,400 B2
• Filed: 02/08/2008
• Issued: 04/09/2013
• Est. Priority Date: 02/09/2007
• Status: Expired due to Fees

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: Toth, Akos
• Primary Examiner(s): Black, Thomas
• Assistant Examiner(s): MARC-COLEMAN, MARTHE Y
• Application Number:
  US12/028,772
• Publication Number:
  US 20080215200A1
• Time in Patent Office: 1,887 Days
• Field of Search: 701/22, 320/163, 320/162, 320/138, 320108-122, 320124-127, 320/132, 320/134, 180/65.285, 180/65.245, 180/65.29, 180/65.4, 180/65.28, 180/65.27, 180/65.1, 180/65.275, 903/902, 903/903, 903/906, 903/907, 318/139, 318/143, 318/157, 318/245, 322/23, 322/28
• US Class Current: 701/22
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60W 10/24 including control of energy storage means
• 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: B60W 20/10 Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60W 2510/244 Charge state
• 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 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 multi-directional power conversion system for providing power to a motor of a hybrid vehicle includes an electric control unit; an electric motor which provides a driving force to the vehicle; a primary energy storage device; and a secondary energy storage device. An energy management system communicates parameters of the energy storage devices to the electronic control unit. A power manipulating device is coupled between the primary energy storage device and the secondary energy storage device that is configured to manage power between the energy sources and deliver electricity external the vehicle.

Claims

1. A drive system of a hybrid vehicle, comprising:

an engine and an electric motor which provide power to the vehicle;

a primary energy storage device which stores electrical energy;

a secondary energy storage device which stores electrical energy;

an electronic control unit that monitors a state of charge of said primary energy storage device and said secondary energy storage device; and

a power converter which is operable to interface with an external electrical grid, said power converter manipulates power transfer between said primary energy storage device and said secondary energy storage device, and charges said secondary energy storage device,

wherein said electronic control unit calculates a charge limit for said secondary energy storage device based on a charge limit table configured to identify a relationship between the voltage of the electrical grid and the charge limit so that said power converter maintains a charge current at the charge limit by setting a secondary state of charge set-point.

2. The hybrid drive system of claim 1, wherein said primary energy storage device stores energy from said engine and from said electrical grid.

3. They hybrid drive system of claim 1, wherein said secondary energy storage device stores energy from said engine and from said electrical grid.

4. The hybrid drive system of claim 1, wherein said power converter is configured to be manipulated to alternate between a charging mode, a drive mode and an electrical grid mode.

5. The hybrid drive system of claim 4, wherein said charging mode performs a AC to DC power conversion, which charges at least one of said primary energy source and said secondary energy source from an AC wall outlet.

6. The hybrid drive system of claim 4, wherein said drive mode performs DC to AC power conversions, such that AC power is produced from at least one of said primary energy storage device and said secondary energy storage device.

7. The hybrid drive system of claim 4, wherein said drive mode allows a DC power conversion from said energy storage devices, either individually or collectively, to propel said hybrid vehicle.

8. The hybrid drive system of claim 4, wherein said electrical grid mode performs a DC to AC power conversion, which allows said energy storage devices to produce energy which is utilized by the electrical grid.

9. A multi-directional power conversion system for providing power to a motor of a hybrid vehicle comprising:

an electric control unit;

an electric motor which provides a driving force to the vehicle;

a primary energy storage device;

a secondary energy storage device;

an energy management system which communicates parameters of said primary energy storage device and said secondary energy storage device to said electronic control unit; and

a power manipulating device which is operable to interface with an external energy system, said power manipulating device is coupled between said primary energy storage device and said secondary energy storage device to manage power sent to said electric motor and to charge said secondary energy storage device,

wherein said energy management system calculates a charge limit for said secondary energy storage device based on a charge limit table configured to identify a relationship between the voltage of the external energy system and the charge limit so that said power manipulating device maintains a charge current at the charge limit by setting a secondary state of charge set-point.

10. The power conversion system of claim 9, wherein said power manipulating device manages power according to different operation modes of said hybrid vehicle.

11. The power conversion system of claim 9, wherein said electric control unit controls said power manipulating device to transfer energy between said secondary energy storage device, said primary energy storage device and said electric motor based on parameters supplied by said energy management system.

12. The power conversion system of claim 9, wherein said electric control unit communicates with said energy management system to alter an operating mode of the vehicle.

13. The power conversion system of claim 9, wherein said electric control unit maintains a state of charge of said primary energy storage device and said secondary energy storage device in accordance with information received from said energy management system.

14. The power conversion system of claim 9, wherein said power manipulating device alters an operation mode of said vehicle to utilize power from said primary energy storage device and said secondary energy storage device, either individually or collectively.

15. The power conversion system of claim 9, wherein said energy management system provides said electric control unit with parameters comprising vehicle speed, engine load, battery temperature, and voltage amounts of said energy storage devices.

16. The power conversion system of claim 9, wherein said electric control unit modifies a flow of energy between said energy storage devices and said electric motor to maintain a state of charge of said energy storage devices in accordance with information received from said energy management system.

17. The power conversion system of claim 9, wherein said electric control unit disables said hybrid drive system when said power conversion system is connected to the external energy system.

18. The power conversion system of claim 9, wherein said power manipulating device comprises a buck-boost converter.

19. The power conversion system of claim 18, wherein said power manipulating device provides DC-to-DC conversion to boost a dc voltage of said primary energy storage device.

20. The power conversion system of claim 18, wherein said power manipulating device provides DC-to-DC conversion to buck or transfer DC voltage from said primary energy storage device to said secondary energy storage device.

21. The power conversion system of claim 9, wherein said power manipulating device provides AC-to-DC conversion to allow charging of said energy storage devices.

22. The power conversion system of claim 9, wherein said power manipulating device is configured to provide a DC-to-AC conversion for sending AC external to the vehicle.

23. The power conversion system of claim 9, wherein said power manipulating device is configured to provide a DC-to-AC conversion, wherein AC is provided to a load external the vehicle.