Electric vehicle with transient current management for DC-DC converter

• US 9,340,114 B2
• Filed: 01/23/2012
• Issued: 05/17/2016
• Est. Priority Date: 01/23/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Ferrel, Mark J., DeDona, Matthew Roger
• Primary Examiner(s): Tran, Thienvu
• Assistant Examiner(s): Stables, David M
• Application Number:
  US13/355,694
• Publication Number:
  US 20130187446A1
• Time in Patent Office: 1,576 Days
• Field of Search: 307/9.1, 307/10.1, 307/117
• US Class Current: 1/1
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2240/525 Temperature of converter or components thereof
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• 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

Abstract

An electric or hybrid electric vehicle includes a battery coupled to a traction motor and a DC-DC power converter for managing transient current demands of vehicle accessories such as an electrical power assisted steering (EPAS) motor or antilock braking system (ABS) with a controller coupled to the power converter that generates a first duty cycle signal to supply current at a first level for a first time period to accommodate transient current for an EPAS, ABS, or other short duration event, and a second duty cycle signal that limits the current to a second level lower than the first level for a second time period upon expiry of the first time period to manage temperature of the converter. The controller may also generate a duty cycle signal based on measured or estimated transistor temperature of the DC-DC converter to lower the current limit when transistor temperature exceeds a threshold.

Claims

1. A vehicle comprising:

a power converter; and

a controller configured to enable the converter to supply current greater than a threshold during a first time period and, upon expiry of the first time period, to operate the converter to supply current with the current supplied from the converter being limited from exceeding the threshold during a longer duration second time period, the threshold being independent of the current supplied from the converter.

2. The vehicle of claim 1 wherein the power converter comprises a DC-DC buck converter.

3. The vehicle of claim 1 further comprising:

an electric power assisted steering (EPAS) motor coupled to the power converter, wherein the first time period accommodates operation of the EPAS motor during a steering maneuver.

4. The vehicle of claim 1 further comprising:

an antilock braking system (ABS) coupled to the power converter, wherein the first time period accommodates operation of the ABS during a braking event.

5. The vehicle of claim 1 wherein the first and second time periods are based on thermal characteristics of the power converter.

6. The vehicle of claim 1 wherein the power converter includes at least one transistor and wherein the first and second time periods are based on temperature of the at least one transistor.

7. The vehicle of claim 1 wherein the second time period is about one-hundred times longer than the first time period.

8. The vehicle of claim 1 wherein:

the controller is further configured to re-enable the converter to supply current greater than the threshold during another first time period after expiry of the second time period in response to a demand for the converter to supply current greater than the threshold.

9. The vehicle of claim 1 wherein:

the threshold is a maximum continuous steady-state current threshold.

10. A method for controlling a vehicle having a battery-powered traction motor and a power converter coupled to the battery, comprising:

in response to a demand for the converter to supply current greater than a threshold, enabling the converter to supply current greater than the threshold during a first time period;

upon expiry of the first time period, operating the converter to supply current with the current supplied from the converter being limited from exceeding the threshold during a longer duration second time period; and

wherein the threshold is independent of the current supplied from the converter.

11. The method of claim 10 wherein the converter includes at least one transistor and the first and second time periods are based on temperature of the at least one transistor.

12. The method of claim 11 wherein the temperature is estimated based on duration and level of current supplied by the power converter.

13. The method of claim 10 wherein the converter comprises a DC-DC buck converter.

14. The method of claim 10 wherein the second time period is on the order of one-hundred times longer than the first time period.

15. The method of claim 10 further comprising performing an antilock braking system (ABS) during the first time period.

16. The method of claim 10 further comprising performing an electrical power assisted steering (EPAS) maneuver during the first time period.

17. The method of claim 10 further comprising:

re-enabling the converter to supply current greater than the threshold during another first time period after expiry of the second time period in response to a demand for the converter to supply current greater than the threshold.

18. The method of claim 10 wherein:

the threshold is a maximum continuous steady-state current threshold.

19. A method for controlling a vehicle having a traction energy source and a power converter, comprising:

in response to a demand for the converter to supply current greater than a threshold, enabling the converter to use energy from the energy source to supply current greater than the threshold during a first time period;

upon expiry of the first time period, operating the converter to use energy from the energy source to supply current with the current supplied from the converter being limited from exceeding the threshold during a second time period longer in duration than the first time period; and

wherein the threshold is independent of the current supplied from the converter.

20. The method of claim 19 further comprising:

re-enabling the converter to use energy from the energy source to supply current greater than the threshold during another first time period after expiry of the second time period in response to a demand for the converter to supply current greater than the threshold.