Charging efficiency using selectable isolation

• US 8,810,208 B2
• Filed: 03/10/2011
• Issued: 08/19/2014
• Est. Priority Date: 03/10/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Krauer, Jean-Pierre, Kalayjian, Nicholas Robert, Nergaard, Troy A.
• Primary Examiner(s): Dunn, Drew A
• Assistant Examiner(s): PELTON, NATHANIEL R
• Application Number:
  US13/045,432
• Publication Number:
  US 20120229098A1
• Time in Patent Office: 1,258 Days
• Field of Search: 320/109, 320/137, 320/140
• US Class Current: 320/140
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

The apparatus for charging an energy storage system (ESS) from an AC line voltage includes a boost stage for converting the AC line voltage to a first ESS charging voltage; an isolation stage, coupled to the boost stage, for converting the first ESS charging voltage to a second ESS charging voltage with the second ESS charging voltage less than the first ESS charging voltage, the isolation stage removing a common mode current between the ESS and the boost stage; a configurator, responsive to a control signal, to set a direct communication of the first ESS charging voltage to the ESS in a bypass mode and to open the direct communication of the first ESS charging voltage to the ESS in an isolation mode; and a controller, coupled to the configurator, for setting the modes responsive to a battery voltage, a peak of the AC line voltage, and a total leakage current at an input of the AC line voltage, the controller asserting the control signal to the configurator.

Claims

1. An apparatus for charging an energy storage system (ESS) from an AC line voltage, comprising:

a boost stage for converting the AC line voltage to a first ESS charging voltage;

an isolation stage, coupled to the boost stage, for converting the first ESS charging voltage to a second ESS charging voltage with the second ESS charging voltage less than the first ESS charging voltage, the isolation stage removing a common mode current between the ESS and the boost stage;

a switching system, responsive to a control signal, to set a direct communication of the first ESS charging voltage to the ESS in a bypass mode and to open the direct communication of the first ESS charging voltage to the ESS in an isolation mode; and

a controller, coupled to the switching system, for setting the modes responsive to a battery voltage, a peak of the AC line voltage, and a total leakage current at an input of the AC line voltage, the controller asserting the control signal to the switching system;

wherein a residual-current device (RCD) trip level is associated with a source for the AC input voltage and wherein the controller asserts the control signal to set the bypass mode when both the battery voltage is above the peak of the AC line and the leakage current is below the RCD trip level.

2. The apparatus of claim 1 wherein the isolation stage includes an isolation transformer and a buck function wherein the switching system bypasses the isolation transformer and the buck function in the bypass mode.

3. The apparatus of claim 2 wherein the switching system includes a pair of contactor relays.

4. The apparatus of claim 1 wherein the total leakage current is calculated responsive to a AC voltages present at each phase relative to ground and a Y impedance of each phase to ground as well as leakages including an average of two input phase voltages across an ESS bus total Y impedance.

5. The apparatus of claim 4 wherein the total leakage current includes an added current safety margin to account at least partially for additional leakage components including harmonics and noise.

6. The apparatus of claim 4 further comprising a leakage sensor to correct the total leakage current.

7. The apparatus of claim 5 further comprising a leakage sensor to correct the total leakage current.

8. A method for charging an energy storage system (ESS) from an AC line voltage, the method comprising the steps of:

a) measuring an AC input voltage for each phase of the AC line voltage;

b) calculating an input leakage current responsive to a Y impedance at an input for the AC line voltage;

c) calculating an ESS leakage current due to an ESS bus Y impedance to ground;

d) testing whether a total leakage current, including a sum of the input leakage current and the ESS leakage current, exceeds a predetermined value;

e) testing whether a peak voltage for the AC line voltage exceeds a voltage of the ESS; and

f) charging the ESS from the AC line voltage using a non-isolated boost stage resulting from bypassing an isolation stage including a buck conversion function when both the tests at step d) and step e) are negative; and

otherwise;

g) charging the ESS from the AC line voltage using both the boost stage and the isolation stage when either the tests at step e) and step f) are affirmative.

9. The method of claim 8 wherein the total leakage current in step d) includes an added margin to at least partially compensate for one or more harmonics and noise.

10. The method of claim 8 further comprising a current sensor for correcting the total leakage current used in step d).