Vehicle system for evaluating a voltage converter

• US 9,302,588 B2
• Filed: 06/29/2012
• Issued: 04/05/2016
• Est. Priority Date: 06/29/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Zhang, Yuan, Degner, Michael W.
• Primary Examiner(s): Ip, Paul
• Assistant Examiner(s): Bouziane, Said
• Application Number:
  US13/537,123
• Publication Number:
  US 20140001985A1
• Time in Patent Office: 1,376 Days
• Field of Search: 363/16, 363/56.02, 363/49, 363/56.05, 363/58, 363/65, 363/70, 363/71, 363/89, 363/132, 363/132.139, 318/139, 318/254
• US Class Current: 1/1
• CPC Class Codes: B60L 2240/527 Voltage
• CPC Class Codes: B60L 2240/529 Current
• CPC Class Codes: B60L 3/003 relating to inverters
• 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 3/06 Limiting the traction current under mechanical overload conditions
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A vehicle is provided with an electric machine and a storage device. The electric machine is configured to provide drive torque and the storage device is configured to supply power to the electric machine. The vehicle includes a variable voltage converter (VVC) that is connected between the storage device and the electric machine. The vehicle also includes a controller that is configured to receive input indicative of a VVC input current and a VVC output voltage. The controller is further configured to selectively disable drive torque responsive to the input.

Claims

1. A vehicle comprising:

an electric machine configured to provide drive torque;

a storage device for supplying power to the electric machine;

a variable voltage converter (VVC) connected between the storage device and the electric machine; and

a controller configured to;

receive input indicative of a VVC input current and a VVC output voltage,

selectively disable drive torque and provide output indicative of a specific defective solid state VVC component responsive to the input,

provide a control signal indicative of an intermediate boost voltage command, wherein the intermediate boost voltage command corresponds to an intermediate voltage value that is greater than a storage device voltage value and less than a boost voltage value,

provide output indicative of an open circuit within a first transistor of the VVC when the VVC output voltage corresponds to the boost voltage value in response to the intermediate boost voltage command, and

disable VVC boost in response to the output by controlling the VVC to allow power to pass from the storage device to the electric machine without boosting the intermediate voltage value.

2. The vehicle of claim 1 further comprising:

a contactor connected between the storage device and the VVC, the contactor being configured to enable the storage device to supply power to the converter when the contactor is closed; and

wherein the controller is further configured to;

provide output indicative of at least one of a short circuit within a second switching unit of the VVC and a defective gate drive circuit communicating with the second switching unit, when the VVC input current exceeds a predetermined threshold current value in response to the contactor being closed, and

disable drive torque in response to the output.

3. The vehicle of claim 1 wherein the controller is further configured to:

provide a control signal indicative of a boost voltage command, wherein the boost voltage command corresponds to a boost voltage value that is greater than a storage device voltage value by a predetermined voltage difference;

provide output indicative of at least one of a short circuit within a first switching unit of the VVC and a defective gate drive circuit communicating with the first switching unit, when the VVC input current exceeds a predetermined threshold current value in response to the boost voltage command; and

disable VVC boost in response to the output.

4. The vehicle of claim 3 wherein the controller is further configured to:

provide output indicative of an open circuit within a second transistor of the VVC when the VVC output voltage does not change in response to the boost voltage command.

5. The vehicle of claim 1 wherein the controller is further configured to:

provide output indicative of an open circuit within a second diode of the VVC when the VVC input current includes a step change to approximately zero Amps in response to the intermediate boost voltage command.

6. The vehicle of claim 1 further comprising:

an inverter connected between the VVC and the electric machine, the inverter being configured to receive DC power from the VVC and provide AC power to the electric machine, and to receive AC power from the electric machine and provide DC power to the VVC; and

a gate drive circuit connected between the controller and the VVC, the gate drive circuit being configured to;

receive at least one control signal from the controller,

amplify the control signal, and

provide the control signal to the VVC for activating the VVC.

7. A vehicle system comprising:

a variable voltage converter (VVC) connected between a battery and an electric machine; and

at least one controller configured to;

receive input indicative of at least one of a VVC input current and a VVC output voltage,

provide a control signal indicative of an intermediate boost voltage command, wherein the intermediate boost voltage command corresponds to an intermediate voltage value that is greater than a battery voltage value and less than a boost voltage value,

provide output indicative of at least one of an open circuit within a first transistor of the VVC and a defective gate drive circuit communicating with the first transistor, when the VVC output voltage corresponds to the boost voltage value in response to the intermediate boost voltage command, and

disable VVC boost in response to the output by controlling the VVC to allow power to pass from the battery to the electric machine without boosting the intermediate voltage value.

8. The vehicle system of claim 7 wherein the controller is further configured to:

receive a key position signal indicative of a vehicle status; and

evaluate VVC performance in response to a change in vehicle status from an off status to an on status.

9. The vehicle system of claim 7 wherein the controller is further configured to:

provide a control signal indicative of a boost voltage command, wherein the boost voltage command corresponds to a boost voltage value that is greater than a battery voltage value by a predetermined voltage difference; and

provide output indicative of an open circuit within a second transistor of the VVC, when the VVC output voltage corresponds to the battery voltage in response to the boost voltage command.

10. The vehicle system of claim 7 wherein the controller is further configured to:

provide a control signal indicative of a boost voltage command, wherein the boost voltage command corresponds to a boost voltage value that is greater than a battery voltage value by a predetermined voltage difference; and

provide output indicative of at least one of a short circuit within a first switching unit of the VVC and a defective gate drive circuit communicating with the first switching unit, when the VVC output voltage decreases to approximately zero Volts in response to the boost voltage command.

11. The vehicle system of claim 10 wherein the controller is further configured to:

provide a control signal indicative of an intermediate boost voltage command, wherein the intermediate boost voltage command corresponds to an intermediate voltage value that is greater than the battery voltage value and less than the boost voltage value; and

provide output indicative of an open circuit within a second diode of the VVC, when the VVC input current includes a step change to approximately zero Amps in response to the intermediate boost voltage command.

12. A variable voltage converter (VVC) evaluation method comprising:

receiving input indicative of a VVC input current and a VVC output voltage; and

providing output indicative of an open circuit within a second diode of the VVC, when the VVC input current step changes to approximately zero Amps in response to an intermediate boost voltage command corresponding to an intermediate boost voltage greater than a battery voltage value and less than a boost voltage value.

13. The method of claim 12 further comprising:

providing a control signal indicative of a boost voltage command, wherein the boost voltage command corresponds to a boost voltage value that is greater than the battery voltage value by a predetermined voltage difference; and

providing output indicative of an open circuit within a second transistor of the VVC, when the VVC output voltage corresponds to the battery voltage value in response to the boost voltage command.

14. The method of claim 12 further comprising:

providing a control signal indicative of a boost voltage command, wherein the boost voltage command corresponds to a boost voltage value that is greater than the battery voltage value by a predetermined voltage difference; and

providing output indicative of a short circuit within a first switching unit of the VVC, when the VVC output voltage decreases to approximately zero Volts in response to the boost voltage command.

15. The method of claim 12 further comprising:

providing a control signal indicative of the intermediate boost voltage command; and

providing output indicative of an open circuit within a first transistor of the VVC, when the VVC input current is greater than or equal to zero Amps in response to the intermediate boost voltage command.

16. The method of claim 12 further comprising:

enabling DC power to pass through the VVC without changing a voltage potential of the DC power, in response to the output indicative of an open circuit within the second diode.

17. The method of claim 12 further comprising:

controlling a contactor connected between the battery and the VVC to close; and

providing output indicative of an open circuit within a first diode of the VVC, when the VVC output voltage corresponds to zero volts in response to the closing of the contactor.