Apparatus for energy transfer using converter and method of manufacturing same

• US 9,024,573 B2
• Filed: 02/27/2012
• Issued: 05/05/2015
• Est. Priority Date: 10/22/2008
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: King, Robert Dean, Steigerwald, Robert L.
• Primary Examiner(s): Dunn, Drew A
• Assistant Examiner(s): Chung, Steve T
• Application Number:
  US13/406,208
• Publication Number:
  US 20120153878A1
• Time in Patent Office: 1,163 Days
• Field of Search: 320/104, 320/140, 180/65.1, 180/65.21, 180/65.29, 307/11, 307/18, 307/19, 307/23, 307 43- 46, 307/48, 307 64- 67
• US Class Current: 320/107
• 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 2210/40 DC to AC converters
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 53/00 Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: B60L 53/56 Mechanical storage means, e.g. fly wheels
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: H02J 3/322 the battery being on-board an electric or hybrid vehicle, e.g. vehicle to grid arrangements [V2G], power aggregation, use of the battery for network load balancing, coordinated or cooperative battery charging
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• CPC Class Codes: H02M 3/155 using semiconductor devices only
• 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
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing

Abstract

According to an aspect of the invention, a motor drive circuit includes a first energy storage device configured to supply electrical energy, a bi-directional DC-to-DC voltage converter coupled to the first energy storage device, a voltage inverter coupled to the bi-directional DC-to-DC voltage converter, and an input device configured to receive electrical energy from an external energy source. The motor drive circuit further includes a coupling system coupled to the input device, to the first energy storage device, and to the bi-directional DC-to-DC voltage converter. The coupling system has a first configuration configured to transfer electrical energy to the first energy storage device via the bi-directional DC-to-DC voltage converter, and has a second configuration configured to transfer electrical energy from the first energy storage device to the voltage inverter via the bi-directional DC-to-DC voltage converter.

Claims

1. A motor drive circuit comprising:

a first energy storage device configured to supply electrical energy;

a second energy storage device configured to supply electrical energy;

a bi-directional DC-to-DC voltage converter coupled to the first and second energy storage devices;

a voltage inverter;

an input device configured to receive electrical energy from an external energy source; and

a switch coupled to the input device, to the bi-directional DC-to-DC voltage converter, and to the first energy storage device, the switch having a first position configured to transfer electrical energy from the first energy storage device, through the switch, and to the voltage inverter via the bi-directional DC-to-DC voltage converter, and having a second position configured to transfer electrical energy from the input device, through the switch, and to the second energy storage device via the bi-directional DC-to-DC voltage converter.

2. The motor drive circuit of claim 1 wherein the first energy storage device comprises one of a battery and a fuel cell.

3. The motor drive circuit of claim 1 wherein the second energy storage device comprises one of a battery and an ultracapacitor.

4. The motor drive circuit of claim 1 wherein the first energy storage device is configured to maximize energy output, and wherein the second energy storage device is configured to maximize power output.

5. The motor drive circuit of claim 1 wherein the bi-directional DC-to-DC voltage converter comprises a bi-directional buck/boost converter.

6. The motor drive circuit of claim 5 wherein the bi-directional buck/boost converter is configured to boost a voltage from the first energy storage device for charging the second energy storage device.

7. The motor drive circuit of claim 1 wherein the input device comprises a receptacle configured to receive an electric plug.

8. The motor drive circuit of claim 1 wherein the input device further comprises a voltage rectifier coupled to the receptacle.

9. The motor drive circuit of claim 8 wherein the voltage rectifier comprises a diode rectifier.

10. The motor drive circuit of claim 1 wherein the switch is configured to transfer electrical energy from a utility grid to the bi-directional DC-to-DC voltage converter.

11. A method of manufacturing a motor drive circuit comprising:

coupling a first energy storage device to a bi-directional buck/boost converter and to a DC-to-AC voltage inverter;

coupling the bi-directional buck/boost converter in parallel with a second energy storage device;

coupling a switch to the bi-directional buck/boost converter, the switch having a first position and a second position;

coupling the switch to the first energy storage device;

coupling an input device to the switch, the input device configured to receive electrical energy from an external energy source;

configuring the switch to cause a transfer of electrical energy from the first energy storage device, through the switch, and to the DC-to-AC voltage inverter via the bi-directional buck/boost converter when positioned in the first position; and

configuring the switch to cause a transfer of electrical energy from the input device, through the switch, and to the second energy storage device via the bi-directional buck/boost converter to charge the second energy storage device when positioned in the second position.

12. The method of claim 11 further comprising incorporating a voltage rectifier into the input device.

13. The method of claim 11 wherein coupling the first energy storage device to the bi-directional buck/boost converter comprises coupling one of a battery and a fuel cell to the bi-directional buck/boost converter;

and

wherein coupling the bi-directional buck/boost converter in parallel with the second energy storage device comprises coupling the bi-directional buck/boost converter in parallel with one of a battery and an ultracapacitor.

14. The method of claim 13 further comprising configuring the bi-directional buck/boost converter to boost electrical energy from the second energy storage to charge the first energy storage device.

15. A traction system comprising:

an electric motor configured to propel a vehicle;

a voltage inverter configured to supply an AC power signal to the electric motor; and

a motor drive circuit configured to supply a DC power signal to the voltage inverter, the motor drive circuit comprising;

a first battery;

a second battery;

a bi-directional buck/boost converter coupled to the first and second batteries, the bi-directional buck/boost converter having a first inductor and a first transistor;

an input device configured to receive electrical energy from an external energy source; and

a multi-position switch having a first position configured to couple the first battery to the voltage inverter via the bi-directional buck/boost converter, so as to transfer electrical energy from the first battery, through the multi-position switch, to the voltage inverter via the bi-directional buck/boost converter and having a second position configured to couple the second battery to the input device via the bi-directional buck/boost converter so as to transfer electrical energy from the input device, through the multi-position switch, to the second battery via the bi-directional buck/boost converter.

16. The traction system of claim 15 wherein the bi-directional buck/boost converter is configured to boost a voltage from the input device for charging the second battery when the multi-switch is positioned in the second position.

17. The traction system of claim 15 wherein the input device comprises:

a receptacle configured to receive an electric plug; and

a voltage rectifier coupled to the receptacle.

18. The traction system of claim 15 wherein the bi-directional buck/boost converter is configured to boost a voltage from the first battery for charging the second battery when the multi-switch is positioned in the first position.

19. The traction system of claim 15 wherein the multi-position switch comprises only the first and second positions.

20. The traction system of claim 15 wherein the multi-position switch is configured to transfer electrical energy from a utility grid to the bi-directional buck/boost converter.