Dual mode range extended electric vehicle

• US 8,463,480 B2
• Filed: 11/13/2012
• Issued: 06/11/2013
• Est. Priority Date: 09/26/2007
• Status: Active Grant

• Current Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Kelty, Kurt Russell, Kohn, Scott Ira, Hermann, Weston Arthur, Straubel, Jeffrey Brian
• Primary Examiner(s): Trammell, James
• Assistant Examiner(s): Malhotra, Sanjeev
• Application Number:
  US13/675,886
• Publication Number:
  US 20130066505A1
• Time in Patent Office: 210 Days
• Field of Search: 701/22, 320/101, 320/104, 320/128, 320/132, 320/137, 324/426, 318/66, 315/86, 257/296, 429/23, 477/2
• US Class Current: 701/22
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 15/2045 for optimising the use of energy
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/28 including control of fuel cells
• CPC Class Codes: B60W 20/13 in order to stay within battery power input or output limits; in order to prevent overcharging or battery depletion
• CPC Class Codes: B60W 2510/24 Energy storage means
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor

Abstract

A dual mode battery charging system and method of use are provided for use in an electric vehicle. The system utilizes at least two user selectable, charging operational modes. In a first operational mode, a state of charge circuit cycles an engine/generator system on/off between a first level and a second level, where the second level is higher than the first level. In a second operational mode, the state of charge circuit cycles the engine/generator system on/off between a third level and a fourth level. After the fourth state of charge has been reached once, the state of charge circuit cycles the engine/generator system on/off between a fifth level and the fourth level, where the fifth level is higher than the third level and lower than the fourth level, and where the fourth level is lower than both the first and second levels.

Claims

1. A system integrated into a vehicle, the system comprising:

a motor, said motor providing propulsion power to said vehicle;

a battery coupled to said motor and providing energy to said motor;

a generator system, said generator system comprising an engine, said engine burning fuel selected from the group consisting of fossil fuels, synthetic fuels and bio-fuels, wherein said generator system provides charging energy for said battery;

an engine control circuit to power on and power off said engine, wherein said engine control circuit powers on said engine when it receives an engine control signal;

a state of charge circuit configured to monitor a battery state of charge and preprogrammed to provide said engine control signal in accordance with an operational mode, wherein said operational mode is selected from at least a first operational mode and a second operational mode, and wherein

the state of charge circuit in said first operational mode provides said engine control signal when said battery state of charge falls below a first state of charge and until said battery state of charge reaches a second state of charge, wherein said second state of charge is higher than said first state of charge, and

the state of charge circuit in said second operational mode provides said engine control signal when said battery state of charge falls below a third state of charge and until said battery state of charge reaches a fourth state of charge, wherein after said fourth state of charge has been reached once the state of charge circuit in said second operational mode provides said engine control signal when said battery state of charge falls below a fifth state of charge and until said battery state of charge reaches said fourth state of charge, wherein said fifth state of charge is higher than said third state of charge, wherein said fourth state of charge is higher than said third state of charge and higher than said fifth state of charge, and wherein said fourth state of charge is lower than both said first state of charge and said second state of charge; and

a user interface coupled to said state of charge circuit and configured to receive a user command selecting said operational mode for the state of charge circuit, wherein said operational mode is selected from at least said first operational mode and said second operational mode.

2. The system of claim 1, wherein said first state of charge is approximately 50% of a full state of charge.

3. The system of claim 2, wherein said second state of charge is approximately 70% of said full state of charge.

4. The system of claim 1, wherein said third state of charge is approximately 20% of a full state of charge.

5. The system of claim 1, wherein said third state of charge is approximately 10% of a full state of charge.

6. The system of claim 5, wherein said fourth state of charge is approximately 23% of a full state of charge.

7. The system of claim 5, wherein said fifth state of charge is approximately 17% of a full state of charge.

8. The system of claim 1, wherein said an average of said first state of charge and said second state of charge is preset at a level of at least 68% of a full state of charge.

9. The system of claim 1, wherein said an average of said first state of charge and said second state of charge is preset at a level of at least 50% of a full state of charge.

10. The system of claim 1, wherein said an average of said third state of charge and said fourth state of charge is preset at a level of at least 20% of a full state of charge.

11. The system of claim 1, wherein said user interface is comprised of a touch screen and wherein said user command is received via a touch registered on said touch screen.

12. The system of claim 1, further comprising at least one operational mode indicator, wherein said operational mode selected via said user interface is indicated by said at least one operational mode indicator.

13. The system of claim 12, wherein said at least one operational mode indicator is comprised of at least one light.

14. The system of claim 1, wherein said user interface is comprised of a touch screen, and wherein said operational mode selected via said user interface is indicated by a message on said touch screen.

15. The system of claim 1, wherein said engine of said generator system is mechanically coupled to a generator.

16. The system of claim 1, wherein a generator is integrated into said engine of said generator system.

17. A method of controlling charging of a battery, wherein the battery is within a vehicle, wherein the vehicle utilizes a motor for propulsive power, and wherein the battery provides energy to the motor, the method comprising the steps of:

providing a user interface;

configuring an operational mode of an on-board generator system in response to a user selection input via said user interface, wherein said operational mode is selected from at least a first operational mode and a second operational mode;

monitoring a current battery state of charge; and

charging said battery using said on-board generator system, wherein said on-board generator system is comprised of an engine, said engine burning fuel selected from the group consisting of fossil fuels, synthetic fuels and bio-fuels, and wherein said step of charging said battery further comprises the steps of powering on and powering off said engine in accordance with said operational mode, wherein in said first operational mode said engine is powered on when said current battery state of charge falls below a first state of charge and powered off when said current battery state of charge reaches a second state of charge, wherein said second state of charge is higher than said first state of charge, and wherein in said second operational mode said engine is powered on when said current battery state of charge falls below a third state of charge and powered off when said current battery state of charge reaches a fourth state of charge, wherein in said second operational mode after said fourth state of charge has been reached once said engine is powered on when said current battery state of charge falls below a fifth state of charge, wherein said fifth state of charge is higher than said third state of charge, wherein said fourth state of charge is higher than said third state of charge and higher than said fifth state of charge, and wherein both said fourth state of charge is lower than both said first state of charge and said second state of charge.