Variable voltage converter (VVC) with integrated battery charger

• US 8,575,778 B2
• Filed: 01/12/2010
• Issued: 11/05/2013
• Est. Priority Date: 01/12/2010
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Chen, Lihua
• Primary Examiner(s): PATEL, RAJNIKANT B
• Application Number:
  US12/685,857
• Publication Number:
  US 20110170318A1
• Time in Patent Office: 1,393 Days
• Field of Search: 363 34- 46, 363/58, 363/59, 363159-161, 363/98, 363/132, 318/34, 318/46, 318/53, 318/58, 318105-108, 318/404, 318/798, 318/801, 318/811, 323/224, 323/225, 323/232, 323/235, 323/259, 323239-242, 290/40.B, 290/40.C, 290/40.E, 290/40.F, 290 52- 53
• US Class Current: 307/66
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A variable voltage converter (VVC) is configured to provide bidirectional voltage boost and buck from an input side to an output side. A VVC can include a voltage control portion and a battery charging portion. When incorporated into an inverter system controller (ISC) for a hybrid electric vehicle, the VVC can be configured to charge a battery during both high and low ISC dc bus voltage conditions. A VVC can be configured to receive power from an ac power source through a plug coupled to the VVC via a soft start rectifier. Accordingly, the VVC with integrated battery charger can be used to charge a battery for a Plug-In Hybrid Electric Vehicle (PHEV) from a standard ac electrical outlet.

Claims

1. A system comprising:

a DC power supply configured to provide power for an electric drive system of a vehicle;

an inverter system control (ISC) circuit coupled to, and configured to receive DC power from, said power supply;

wherein said ISC circuit includes a voltage converter portion, and an inverter portion configured to provide power to a permanent magnet synchronous machine (PMSM) for said electric drive system; and

wherein said ISC circuit is configured for bidirectional voltage boost operation between its inverter portion and said DC power supply.

2. The system of claim 1, wherein said ISC circuit comprises a first phase leg for coupling with said inverter, and a second phase leg for coupling with said power supply.

3. The system of claim 2, wherein said first phase leg is configured to control a DC bus voltage and said second phase leg is configured to charge said power supply.

4. The system of claim 1, further comprising a diode rectifier with a soft start coupled to said ISC circuit, and a plug configured to connect said diode rectifier with an ac power source;

wherein said ISC circuit is configured to charge said power supply using power provided by said ac power source.

5. The system of claim 1, further comprising said permanent magnet synchronous machine (PMSM) coupled to said inverter.

18. The system of claim 1, wherein said ISC circuit is configured for providing energy to said DC power supply when a voltage V_I between said voltage converter portion of said ISC circuit and said inverter portion is lower than a voltage V_B between said voltage converter portion and said DC power supply.

6. A system comprising:

a variable voltage converter (VVC) having an integrated battery charger portion configured to provide energy to a fraction battery for an electrified vehicle, and having a voltage control portion coupled to said battery charger portion by an inductor;

an inverter coupled to said VVC and configured to provide power to a permanent magnet synchronous machine (PMSM) for said electrified vehicle; and

wherein said VVC is configured to receive DC power input from said traction battery.

7. The system of claim 6, further comprising a soft start diode rectifier coupled to said VVC and configured to receive ac power via an ac power plug.

8. The system of claim 6, further comprising said traction battery coupled to said VVC, wherein said VVC is configured to charge said fraction battery.

9. The system of claim 6, wherein said VVC is configured to boost a DC voltage received at its inverter side.

10. The system of claim 6, wherein said integrated battery charger comprises a phase leg having a first transistor paired in parallel with a first diode, and a second transistor paired in parallel with a second diode.

11. A variable voltage converter (VVC), comprising:

a battery charging portion configured to charge a traction battery for an electrified vehicle;

a voltage control portion configured to control an output voltage;

wherein said battery charging portion and said voltage control portion are directly coupled to an inductor disposed therebetween; and

wherein said VVC is configured to provide bidirectional voltage boost operation.

12. The VVC of claim 11, wherein said voltage control portion comprises a first phase leg having a first switching unit and a second switching unit, and said battery charging portion comprises a second phase leg having a third switching unit and a fourth switching unit.

13. The VVC of claim 12, wherein said first phase leg is coupled to said inductor at a first node between said first and second switching units, and said second phase leg is coupled to said inductor at a second node between said third and fourth switching units.

14. The VVC of claim 11, wherein said VVC is configured to receive ac power via an ac plug coupled to said VVC via a diode rectifier with a soft start.

15. The VVC of claim 14, wherein said VVC is configured to provide power provided via said ac plug to a battery coupled to said VVC in order to charge said battery.

16. The VVC of claim 14, wherein said VVC is configured to couple to said diode rectifier at a first node positioned between said inductor and said first phase leg, and to couple to said diode rectifier at a second node positioned between said first and second phase legs along a direct current (DC) bus.

17. The VVC of claim 11, wherein said third switching unit comprises a transistor arranged in parallel with a diode.

19. The VVC of claim 11, wherein said VVC is configured for providing said bidirectional voltage boost operation during low and high speed operation of said electrified vehicle.

20. The VVC of claim 11, wherein said VVC is configured for bidirectional buck operation.