High power low voltage electrified powertrain

• US 9,484,852 B2
• Filed: 04/07/2014
• Issued: 11/01/2016
• Est. Priority Date: 04/07/2014
• Status: Active Grant

• Current Assignee: FCA US LLC (Stellantis NV)
• Original Assignee: FCA US LLC (Stellantis NV)
• Inventors: Timmons, Adam, Sathyan, Anand, Mirowski, Marian
• Primary Examiner(s): Chan, Kawing
• Assistant Examiner(s): BROWN, BRADLEY R
• Application Number:
  US14/246,636
• Publication Number:
  US 20150288313A1
• Time in Patent Office: 939 Days
• Field of Search: 318/139
• US Class Current: 1/1
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 15/28 without contact making and breaking, e.g. using a transductor
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2220/12 Induction machines
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/58 with more than three phases
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: H02P 25/22 Multiple windings; Windings for more than three phases
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• 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 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

An electrified powertrain includes an electric motor having four or more coils corresponding to four or more AC phases and configured to generate drive torque to propel an electrified vehicle. The electrified powertrain also includes a low voltage electrical system comprising independent battery modules each configured to output a separate low DC voltage, and a power inverter module (PIM) configured to receive each of the separate low DC voltages from the battery modules, generate a separate low AC voltage for each AC phase using all of or fewer than all of the separate low DC voltages, and output the separate low AC voltages to the coils of the electric motor to drive the electric motor to generate the drive torque to propel the electrified vehicle, wherein none of the separate low DC voltages are electrically isolated and none of the separate AC voltages are considered high voltage.

Claims

1. A high power, low voltage electrified powertrain for an electrified vehicle, the electrified powertrain comprising:

a single electric motor having four or more coils corresponding to four or more alternating current (AC) phases, wherein the single electric motor is the only electric motor of the electrified powertrain that is configured to generate drive torque that is sufficient to propel the electrified vehicle; and

a low voltage electrical system comprising;

four or more independent battery modules each configured to output a separate low direct current (DC) voltage; and

a single power inverter module (PIM) configured to;

receive each of the separate low DC voltages from the battery modules;

generate (i) a separate low AC voltage for each AC phase using the separate low DC voltages or (ii) a separate low AC voltage for each AC phase using fewer than all of the separate low DC voltages; and

output the separate low AC voltages to the coils of the electric motor to drive the electric motor to generate the drive torque that is sufficient to propel the electrified vehicle,

wherein none of the separate low DC voltages are electrically isolated,

wherein a sum of the separate low DC voltages is greater than 100 volts DC.

2. The electrified powertrain of claim 1, wherein the four or more independent battery modules are not connected in series.

3. The electrified powertrain of claim 1, wherein the PIM includes a plurality of transistors, and wherein the PIM is configured to control the plurality of transistors to (i) generate the low AC voltages for the AC phases using the separate low DC voltages or (ii) generate the low AC voltages for the AC phases using fewer than all of the separate low DC voltages.

4. The electrified powertrain of claim 3, wherein the PIM is configured to control the plurality of transistors to achieve a higher efficiency of the electric motor.

5. The electrified powertrain of claim 1, wherein each of the separate low DC voltages is less than a minimum DC voltage that requires electrical isolation.

6. The electrified powertrain of claim 5, wherein the minimum DC voltage that requires electrical isolation is approximately 60 Volts DC.

7. The electrified powertrain of claim 1, wherein each of the separate low AC voltages is less than an AC voltage that is considered high voltage.

8. The electrified powertrain of claim 7, wherein the AC voltage that is considered high voltage is approximately 30 volts AC.

9. The electrified powertrain of claim 1, wherein the electric motor has six coils and six corresponding AC phases.

10. The electrified powertrain of claim 1, wherein the electric motor has nine coils and nine corresponding AC phases.

11. The electrified powertrain of claim 1, wherein the electrified vehicle is a battery electric vehicle (BEV).

12. The electrified powertrain of claim 1, wherein the electrified vehicle is an extended-range electric vehicle (EREV), a fuel cell electric vehicle (FCEV), a hybrid electric vehicle (HEV), or a plug-in HEV (PHEV).

13. The electrified powertrain of claim 1, wherein the PIM is configured to generate the separate low AC voltage for each AC phase using fewer than all of the separate low DC voltages.

14. A high power, low voltage electrified powertrain, for an electrified vehicle, the electrified powertrain comprising:

a single electric motor having four or more coils corresponding to four or more alternating current (AC) phases, wherein the single electric motor is the only electric motor of the electrified powertrain that is configured to generate drive torque that is sufficient to propel the electrified vehicle; and

a low voltage electrical system comprising;

four or more independent battery modules each configured to output a separate low direct current (DC) voltage; and

a single power inverter module (PIM) configured to;

receive each of the separate low DC voltages from the battery modules;

generate (i) a separate low AC voltage for each AC phase using the separate low DC voltages or (ii) a separate low AC voltage for each AC phase using fewer than all of the separate low DC voltages; and

output the separate low AC voltages to the coils of the electric motor to drive the electric motor to generate the drive torque that is sufficient to propel the electrified vehicle,

wherein none of the separate low DC voltages are electrically isolated,

wherein the single electric motor is approximately a 100 kilowatt electric motor capable of receiving up to 250 amperes of current.

15. A high power, low voltage electrified powertrain, for an electrified vehicle, the electrified powertrain comprising:

a single electric motor having four or more coils corresponding to four or more alternating current (AC) phases, wherein the single electric motor is the only electric motor of the electrified powertrain that is configured to generate drive torque that is sufficient to propel the electrified vehicle; and

a low voltage electrical system comprising;

four or more independent battery modules each configured to output a separate low direct current (DC) voltage; and

a single power inverter module (PIM) configured to;

receive each of the separate low DC voltages from the battery modules;

generate (i) a separate low AC voltage for each AC phase using the separate low DC voltages or (ii) a separate low AC voltage for each AC phase using fewer than all of the separate low DC voltages; and

output the separate low AC voltages to the coils of the electric motor to drive the electric motor to generate the drive torque that is sufficient to propel the electrified vehicle,

wherein none of the separate low DC voltages are electrically isolated,

wherein the sum of the separate low DC voltages is approximately 400 volts DC.