Devices and methods for the safe driving, charging and energy recovery operation of an electric vehicle

• US 9,272,626 B2
• Filed: 03/28/2012
• Issued: 03/01/2016
• Est. Priority Date: 03/30/2011
• Status: Active Grant

• Current Assignee: Bender GmbH & Co. KG
• Original Assignee: Bender GmbH & Co. KG
• Inventors: Sellner, Harald, Moell, Winfried, Oehler, Matthias, Hofheinz, Wolfgang
• Primary Examiner(s): Kitov, Zeev V
• Application Number:
  US13/432,265
• Publication Number:
  US 20120249070A1
• Time in Patent Office: 1,434 Days
• US Class Current: 1/1
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• 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 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/63 in response to network capacity
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 55/00 Arrangements for supplying energy stored within a vehicle to a power network, i.e. vehicle-to-grid [V2G] arrangements
• CPC Class Codes: H02H 3/05 with means for increasing reliability, e.g. redundancy arrangements for logic circuits H03K19/003
• CPC Class Codes: H02H 3/26 responsive to difference between voltages or between currents; responsive to phase angle between voltages or between currents
• CPC Class Codes: H02H 3/33 using summation current transformers H02H3/347 takes precedence
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• 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: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 10/126 : the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

The invention relates to a method and an electrical protection and monitoring device with an insulation monitoring instrument and a differential current monitoring instrument in an electric vehicle for safe driving operation and also for safe charging and energy recovery operation of the electric vehicle at a charging station. The invention further relates to a device for the safe charging and energy recovery operation of an electric vehicle at a charging station with electrical protection and monitoring devices.

Claims

1. An electrical protection and monitoring device in an electric vehicle for safe driving operation and also for safe charging of a rechargeable energy store of the electric vehicle with an unearthed IT network as an on-board electrical system and energy recovery operation from the energy store of the electric vehicle at a charging station, the electrical protection and monitoring device comprising:

(a) an insulation monitoring instrument connected to the on-board electrical system of the electric vehicle; and

(b) a differential current monitoring instrument in the electric vehicle connected to a connected section of the power supply network to monitor a residual current.

2. The electrical protection and monitoring device according to claim 1, wherein the insulation monitoring instrument and the differential current monitoring instrument are integrated in a structural unit as a combined monitoring instrument.

3. The electrical protection and monitoring device according to claim 2, wherein the combined monitoring instrument includes at least one communication interface that can actuate switching equipment present in the electric vehicle.

4. The electrical protection and monitoring device according to claim 3, wherein the communication interface is designed as a PWM output, a relay output, an open-collector output or a bus interface.

5. The electrical protection and monitoring device according to claim 1, further comprising

(c) a switch mechanism to disconnect the on-board electrical system from a charging station.

6. The electrical protection and monitoring device according to claim 1, wherein the differential current monitoring instrument is designed for universal-current-sensitive detection of residual currents.

7. The electrical protection and monitoring device according to claim 1, further comprising

(c) a circuit designed to detect higher-frequency residual currents.

8. The electrical protection and monitoring device according to claim 2, wherein the combined monitoring instrument includes a self-monitoring unit.

9. A method for the safe driving operation of an electric vehicle with an unearthed IT network as an on-board electrical system and an electrical protection and monitoring device and also for the safe charging of a rechargeable energy store of the electric vehicle as an on-board electrical system and energy recovery operation from the energy store of the electric vehicle at a charging station, the method comprising the steps of:

(a) monitoring an insulation resistance between at least one active conductors of an on-board electrical system and a vehicle chassis with an insulation monitoring instrument during the driving operation;

(b) monitoring the insulation resistance before starting charging, and monitoring the differential current in the electric vehicle when the electric vehicle is connected to the charging station,

wherein an entire charging system comprises the electric vehicle, the charging station and a charging cable being monitored; and

(c) deactivating the differential current monitoring instrument while in drive mode.

10. The method according to claim 9,

wherein, when the electric vehicle is connected to the charging station, the method comprising the additional steps of:

(i) connecting the electric vehicle to the charging station;

(ii) monitoring the insulation with an insulation monitoring instrument determine an insulation resistance for the electric vehicle before the charging station is switched on;

(iii) clearing a charging/recovery process if insulation resistance is adequate,

(iv) switching off the insulation monitoring instrument following clearance of the charging/recovery process;

(v) monitoring a residual current in the charging system with a differential current monitoring instrument during the charging/recovery operation; and

(v) disconnecting the electric vehicle from the charging station if a given residual current value is exceeded.

11. The method according to claim 10, wherein the residual current is detected as a differential current or as a protective conductor current.

12. The method according to claim 9, wherein the differential current monitoring instrument is universal-current-sensitive.

13. The method according to claim 9, wherein a warning signal is issued if the value falls below a response value for the insulation resistance.

14. The method according to claim 9, wherein an entry is made in a fault memory of the electric vehicle if the value falls below a response value for the insulation resistance.

15. The method according to claim 9, wherein the insulation monitoring instrument and differential current monitoring instrument issue information to the driver and generate disconnection signals in case of a fault.

16. The method according to claim 9, wherein the insulation monitoring instrument and differential current monitoring instrument conduct self-monitoring.

17. A device for the safe charging of a rechargeable energy store of an electric vehicle with an unearthed IT network as an on-board electrical system and energy recovery operation from the energy store of the electric vehicle at a charging station, the device comprising:

an electrical protection device and an electrical monitoring device operably connected to protect against electrical shocks creating a comprehensive electrical safety system, wherein

the electrical protection device and the electrical monitoring device are disposed in the electric vehicle as a vehicle-based electrical protection and monitoring device and in the charging station, or a charging cable, or the charging station and the charging cable, as charging station-based electrical protection and monitoring devices.

18. The device according to claim 17, wherein the vehicle-based electrical protection and monitoring device comprises

(a) an insulation monitoring instrument connected to the on-board electrical system of the electric vehicle;

and

(b) a differential current monitoring instrument in the electric vehicle connected to a connected section of the power supply network to monitor a residual current.

19. The device according to claim 17, wherein the electrical protection and monitoring devices are designed for different operating modes, including energy recovery.

20. The device according claim 17, wherein the charging station-based protection devices include an insulation monitoring instrument.

21. The device according to claim 17, wherein the charging station-based electrical protection and monitoring devices include a differential current monitoring instrument.

22. The device according to claim 17, wherein the charging station-based electrical protection and monitoring devices include an electronically controlled, reconnectable protection switch.

23. The device according to claim 17, wherein the charging station-based electrical protection and monitoring devices exhibit a switch-on relay.

24. The device according to claim 18, further comprising

a voltage and frequency monitoring instrument, wherein the voltage and frequency monitoring instrument monitors the power to be fed back into a stationary power supply network.

25. The device according to claim 17, wherein a plurality of components of the electrical protection and monitoring devices are installed in a control mechanism, which is integrated into a line connection between the charging station and the electric vehicle.

26. The device according to claim 24, wherein the insulation monitoring instrument, the differential current monitoring instrument and the voltage and frequency monitoring instrument are integrated in a structural unit.