Electric automobile and integrated control system thereof

• US 9,493,088 B2
• Filed: 12/31/2012
• Issued: 11/15/2016
• Est. Priority Date: 12/31/2011
• Status: Active Grant

• Current Assignee: BYD Company Limited
• Original Assignee: BYD Company Limited, Shenzhen BYD Auto R&D Company Limited (BYD Company Limited)
• Inventors: Wei, Wei, Wang, Hongjun, Zhou, Wei
• Primary Examiner(s): Olszewski, John R
• Assistant Examiner(s): Foster, Gerrad A
• Application Number:
  US14/370,041
• Publication Number:
  US 20150006008A1
• Time in Patent Office: 1,415 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/006 to power outlets
• CPC Class Codes: B60L 2210/12 Buck converters
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2210/42 Voltage source inverters
• CPC Class Codes: B60L 2240/527 Voltage
• CPC Class Codes: B60L 2240/529 Current
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2260/22 Standstill, e.g. zero speed
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 2270/147 electro magnetic [EMI]
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 50/51 : characterised by AC-motors
• CPC Class Codes: B60L 50/52 : characterised by DC-motors
• CPC Class Codes: B60L 50/60 : using power supplied by batteries in combination with fuel cells B60L50/75
• 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 53/60 : Monitoring or controlling charging stations
• 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: B60L 58/10 : for monitoring or controlling batteries
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/25 : by controlling the electric load
• CPC Class Codes: H02J 2207/20 : Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 2207/40 : adapted for charging from various sources, e.g. AC, DC or multivoltage
• CPC Class Codes: H02J 2310/48 : for electric vehicles [EV] or hybrid vehicles [HEV]
• 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 5/00 : Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 7/0036 : using connection detecting circuits H02J7/0034 takes precedence
• CPC Class Codes: H02J 7/0063 : with circuits adapted for supplying loads from the battery
• CPC Class Codes: H02J 7/0068 : Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/007182 : in response to battery voltage
• CPC Class Codes: H02J 7/007194 : of the battery
• CPC Class Codes: H02J 7/02 : for charging batteries from ac mains by converters
• 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: H02J 7/345 : using capacitors as storage or buffering devices
• CPC Class Codes: H04B 3/542 : the information being in digital form
• 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 30/12 : Remote or cooperative charging
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

An integrated control system for an electric vehicle, comprising: an integrated driving and charge-discharge controller connected with a power battery via a high-voltage distribution box, connected with a motor and a charge-discharge socket respectively, and configured to drive the motor when the electric vehicle is in a driving mode and to control to charge and discharge the power battery via the charge-discharge socket when the electric vehicle is in a charge-discharge mode; an auxiliary high-voltage element connected with the power battery via the high-voltage distribution box; a first DC/DC module connected with the power battery via the high-voltage distribution box; and a controller connected with the high-voltage distribution box and configured to control the high-voltage distribution box so as to perform a pre-charging via the high-voltage distribution box before the integrated driving and charge-discharge controller, the auxiliary high-voltage element and the first DC/DC module are powered on.

Claims

1. An integrated control system for an electric vehicle, comprising:

a power battery;

a high-voltage distribution box connected with the power battery;

an integrated driving and charge-discharge controller, connected with the power battery via the high-voltage distribution box, and connected with a motor and a charge-discharge socket respectively, and configured to drive the motor when the electric vehicle is in a driving mode and to control to charge and discharge the power battery via the charge-discharge socket when the electric vehicle is in a charge-discharge mode;

an auxiliary high-voltage element connected with the power battery via the high-voltage distribution box;

a first DC/DC module connected with the power battery via the high-voltage distribution box; and

a controller connected with the high-voltage distribution box and configured to control the high-voltage distribution box so as to perform a pre-charging via the high-voltage distribution box before the integrated driving and charge-discharge controller, the auxiliary high-voltage element and the first DC/DC module are powered on,

wherein the high-voltage distribution box comprises;

a first pre-charging control module and a first switch connected in parallel with the first pre-charging control module, wherein the first pre-charging control module has a first terminal connected with a first terminal of the power battery and a second terminal connected with a first terminal of the integrated driving and charged-discharged controller, and the first switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the integrated driving and charge-discharge controller;

a second pre-charging control module and a second switch connected in parallel with the second pre-charging control module, wherein the second pre-charging control module has a first terminal connected with the first terminal of the power battery and a second terminal connected with a first terminal of the first DC/DC module, and the second switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the first DC/DC module;

a third pre-charging control module and a third switch connected in parallel with the third pre-charging control module, wherein the third pre-charging control module has a first terminal connected with the first terminal of the power battery and a second terminal connected with a first terminal of the auxiliary high-voltage element, and the third switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the auxiliary high-voltage element;

a fourth switch having a first terminal connected with the first terminal of the power battery and a second terminal connected with a second terminal of the integrated driving and charge-discharge controller; and

a fifth switch having a first terminal connected with a second terminal of the power battery and a second terminal connected with a third terminal of the integrated driving and charge-discharge controller, a second terminal of the first DC/DC module and a second terminal of the auxiliary high-voltage element respectively.

2. The integrated control system according to claim 1, wherein when the electric vehicle is in the driving mode or the charge-discharge mode, the controller controls to pre-charge the integrated driving and charge-discharge controller via the first pre-charging control module and turns on the fourth switch, and controls the first pre-charging control module to turn off and turns on the first switch when a bus voltage of the integrated driving and charge-discharge controller is a predetermined multiple of a voltage of the power battery.

3. The integrated control system according to claim 2, wherein after the first switch is turned on, the controller further controls to pre-charge the auxiliary high-voltage element via the third pre-charging control module;

and when the bus voltage of the auxiliary high-voltage element is a predetermined multiple of the voltage of the power battery, the controller controls the third pre-charging control module to turn off and turns on the third switch.

4. The integrated control system according to claim 3, wherein when the electric vehicle is in the driving mode and the third switch is turned on, the controller further controls to pre-charge the first DC/DC module via the second pre-charging control module;

and when a bus voltage of the first DC/DC module is a predetermined multiple of the voltage of the battery, the controller controls the second pre-charging control module to turn off and turns on the second switch.

5. The integrated control system according to claim 1, further comprising:

a cooling module configured to cool the integrated control system.

6. The integrated control system according to claim 1, wherein the integrated driving and charge-discharge controller comprises:

a bidirectional DC/DC module having a first DC terminal connected with the second terminal of the fourth switch and a second DC terminal connected with second terminals of the first pre-charging control module and the first switch respectively, wherein the first DC terminal is a common DC terminal for an input to and an output from the bidirectional DC/DC module;

a driving control switch having a first terminal connected with the second terminal of the power battery and a second terminal connected with a third DC terminal of the bidirectional DC/DC module;

a bidirectional DC/AC module having a first DC terminal connected with the second terminal of the driving control switch and a second DC terminal connected with the second terminal of the power battery;

a motor control switch having a first terminal connected with an AC terminal of the bidirectional DC/AC module and a second terminal connected with the motor;

a charge-discharge control module having a first terminal connected with the AC terminal of the bidirectional DC/AC module and a second terminal connected with the charge-discharge socket; and

a controller module connected with the driving control switch, the motor control switch and the charge-discharge control module respectively, and configured to control the driving control switch, the motor control switch and the charge-discharge control module according to a current operation mode of a power system of the electric vehicle.

7. The integrated control system according to claim 6, wherein when the current operation mode of the power system is the driving mode, the controller module controls the fifth switch to turn on to stop the bidirectional DC/DC module, controls the motor control switch to turn on, and controls the charge-discharge control module to turn off.

8. The integrated control system according to claim 7, wherein when the current operation mode of the power system is the charge-discharge mode, the controller module controls the fifth switch to turn off to start the bidirectional DC/DC module, controls the motor control switch to turn off, and controls the charge-discharge control module to turn on.

9. The integrated control system according to claim 6, wherein the bidirectional DC/DC module comprises:

a first switching transistor and a second switching transistor connected in series, connected between the first DC terminal and the third DC terminal of the bidirectional DC/DC module, and controlled by the controller module, in which a first node is defined between the first switching transistor and the second switching transistor;

a first diode connected with the first switching transistor in inverse-parallel;

a second diode connected with the second switching transistor in inverse-parallel;

a first inductor having a first terminal connected with the first node and a second terminal connected with the second terminal of the power battery; and

a first capacitor having a first terminal connected with the second terminal of the first inductor and a second terminal connected with the first terminal of the power battery.

10. The integrated control system according to claim 6, wherein the integrated driving and charge-discharge controller further comprises:

a leakage current reducing module connected between the first DC terminal and the third DC terminal of the bidirectional DC/DC module.

11. The integrated control system according to claim 10, wherein the leakage current reducing module comprises:

a second capacitor and a third capacitor, in which the second capacitor has a first terminal connected with a first terminal of the third capacitor and a second terminal connected with the first DC terminal of the bidirectional DC/DC module, the third capacitor has a second terminal connected with the third DC terminal of the bidirectional DC/DC module, and a second node is defined between the second capacitor and the third capacitor.

12. The integrated control system according to claim 11, wherein the integrated driving and charge-discharge controller further comprises:

a filtering module connected between the bidirectional DC/AC module and the charge-discharge control module.

13. The integrated control system according to claim 12, wherein the integrated driving and charge-discharge controller further comprises:

a filtering control module connected between the second node and the filtering module, controlled by the controller module, and configured to control the filtering control module to turn off when the current operation mode of the power system is the driving mode.

14. The integrated control system according to claim 12, further comprising:

a second pre-charging control module connected with the charge-discharge control module in parallel and configured to control to pre-charge a capacitor in the filtering module.

15. The integrated control system according to claim 6, wherein the charge-discharge control module comprises:

a three-phase switch and/or a single-phase switch configured to implement a three-phase charge-discharge or a single-phase charge-discharge.

16. An electric vehicle comprising an integrated control system, wherein the integrated control system comprises:

a power battery;

a high-voltage distribution box connected with the power battery;

an integrated driving and charge-discharge controller connected with the power battery via the high-voltage distribution box, connected with a motor and a charge-discharge socket respectively, and configured to drive the motor when the electric vehicle is in a driving mode and to control to charge and discharge the power battery via the charge-discharge socket when the electric vehicle is in a charge-discharge mode;

an auxiliary high-voltage element connected with the power battery via the high-voltage distribution box;

a first DC/DC module connected with the power battery via the high-voltage distribution box; and

a controller connected with the high-voltage distribution box and configured to control the high-voltage distribution box so as to perform a pre-charging via the high-voltage distribution box before the integrated driving and charge-discharge controller, the auxiliary high-voltage element and the first DC/DC module are powered on,

wherein the high-voltage distribution box comprises;

a first pre-charging control module and a first switch connected in parallel with the first pre-charging control module, wherein the first pre-charging control module has a first terminal connected with a first terminal of the power battery and a second terminal connected with a first terminal of the integrated driving and charge-discharge controller, and the first switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the integrated driving and charge-discharge controller;

a second pre-charging control module and a second switch connected in parallel with the second pre-charging control module, wherein the second pre-charging control module has a first terminal connected with the first terminal of the power battery and a second terminal connected with a first terminal of the first DC/DC module, and the second switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the first DC/DC module;

a third pre-charging control module and a third switch connected in parallel with the third pre-charging control module, wherein the third pre-charging control module has a first terminal connected with the first terminal of the power battery and a second terminal connected with a first terminal of the auxiliary high-voltage element, and the third switch has a first terminal connected with the first terminal of the power battery and a second terminal connected with the first terminal of the auxiliary high-voltage element;

a fourth switch having a first terminal connected with the first terminal of the power battery and a second terminal connected with a second terminal of the integrated driving and charge-discharge controller; and

a fifth switch having a first terminal connected with a second terminal of the power battery and a second terminal connected with a third terminal of the integrated driving and charge-discharge controller, a second terminal of the first DC/DC module and a second terminal of the auxiliary high-voltage element respectively.