System for charging a rechargeable battery of an electric vehicle

• US 9,748,795 B2
• Filed: 03/01/2013
• Issued: 08/29/2017
• Est. Priority Date: 09/03/2010
• Status: Active Grant

• Current Assignee: Bayerische Motoren Werke AG
• Original Assignee: Bayerische Motoren Werke AG
• Inventors: Jung, Merten, Mueller, Patrick, Griessbach, Robert, Schimanek, Thomas, Hieber, Christian
• Primary Examiner(s): Berhanu, Samuel
• Assistant Examiner(s): Rankine, Tarikh
• Application Number:
  US13/781,973
• Publication Number:
  US 20130175990A1
• Time in Patent Office: 1,642 Days
• Field of Search: 320109
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• 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: 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 5/00 Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/14 for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

An electric vehicle includes an electric machine, a generator generating a first AC output current, an internal combustion engine driving the generator, and a first electric plug-in charging device. When the engine is started, the generator supplies the battery with charging power. The first plug-in charging device is geometrically configured to be connectable with single phase AC power mains to supply the battery with charging power in a vehicle deactivated state. The first plug-in charging device is configured for a maximum electric power voltage load of 240 volts and a maximum current strength of 32 amperes. A second electric plug-in charging device is integrated into the vehicle. A DC charging station is connectable to the second charging device in the deactivated state so the DC charging station is usable either exclusively or simultaneously with the single phase AC power mains for charging the battery.

Claims

1. A system for charging a rechargeable battery of an electric vehicle, the system comprising:

an electric machine configured to convert electrical power into mechanical power for driving the electric vehicle;

a generator configured to generate a first AC output current;

an internal combustion engine configured to drive the generator to generate the first AC output current and being startable during a driving mode of the electric vehicle; and

a first electric plug-in charging device,

wherein the generator is configured to, at least temporarily, be an electric power source for supplying the rechargeable battery with charging power after the internal combustion engine is started,

wherein the first plug-in charging device is geometrically configured to be connectable, via a first charging cable, with single phase AC power mains supplying a second AC output current, in order to supply the rechargeable battery with charging power as an electric power source in a deactivated state of the electric vehicle,

wherein the first plug-in charging device is operatively configured for a maximum electric power voltage load of at least 240 volts and a maximum current strength of at least 32 amperes,

wherein a second electric plug-in charging device is integrated into the electric vehicle and is connectable, via a second charging cable, to a DC charging station that supplies a first direct current, in the deactivated state of the electric vehicle so that in the deactivated state the DC charging station is usable as selected between one of;

exclusively and simultaneously with the single phase AC power mains, as an electric power source for supplying the rechargeable battery with charging power,

wherein a high power switch operatively configured to interrupt the first direct current,

wherein the first AC output current is rectified into a second direct current via a first AC/DC converter and a second AC/DC converter, the first and second AC/DC converters being coupled in parallel, and

wherein the second AC/DC converter and the high power switch are geometrically integrated into a modularly-configured combination charging unit.

2. The system according to claim 1, wherein the second direct current supplies the electric machine with electric power via a DC/AC converter coupled upstream of the electric machine or supplies the electric machine and simultaneously charges the rechargeable battery.

3. The system according to claim 1,

wherein the second AC output current is rectified into a third direct current by the first AC/DC converter and the second AC/DC converter;

and

wherein the third direct current charges the rechargeable battery.

4. The system according to claim 1,

wherein the first AC/DC converter is operatively configured for a maximum input power of at least 230 volts×

16 amperes; and

wherein the second AC/DC converter is operatively configured for a maximum input power of at least 230 volts×

16 amperes.

5. The system according to claim 1, wherein the high power switch is a DC contactor.

6. The system according to claim 5,

wherein the second AC/DC converter and the DC contactor are geometrically integrated into a combination charging unit;

and

wherein the parallel coupling of the first and second AC/DC converters occurs either outside of the combination charging unit or at the combination charging unit.

7. The system according to claim 5, wherein the combination charging unit, the first AC/DC converter, the first plug-in charging device and the second plug-in charging device are functionally controlled via at least one control device.

8. The system according to claim 6, wherein the first AC/DC converter, the combination charging unit, the second AC/DC converter and the at least one control device are components of the electric vehicle.

16. The system according to claim 1, wherein the combination charging unit, comprising the second AC/DC converter and the high power switch, is disposed in a housing that is removeably distinct from the vehicle.

18. The system according to claim 16, the second AC/DC converter is integrated into the combination charging unit so as to be mechanically disconnectable therefrom, and removable from the housing.

9. An electric vehicle, comprising:

a rechargeable battery;

an electric machine;

a generator operatively configured to generate a first AC output current;

an internal combustion engine operatively configured to drive the generator to generate the first AC output current and being startable during a driving mode of the electric vehicle;

a first electric plug-in charging device; and

a second electric plug-in charging device,

wherein the first plug-in charging device is geometrically configured to be connectable via a first charging cable with single phase AC power mains supplying a second AC output current in order to supply the rechargeable battery with charge power in a deactivated state of the electric vehicle,

wherein the first plug-in charging device is operatively configured for a maximum electric power voltage load of 240 volts and a maximum current strength of 32 amperes,

wherein the generator is usable, when the internal combustion engine is started, for supplying the rechargeable battery with charge power,

wherein the second electric plug-in charging device is operatively configured to be connectable, via a second charging cable, to a DC charging station supplying a first direct current in the deactivated state of the electric vehicle, whereby the DC charging station is usable as selected between one of;

exclusively and simultaneously with the single phase AC power mains, to supply the rechargeable battery with charge power,

wherein a high power switch operatively configured to interrupt the first direct current,

wherein a first AC/DC converter and a second AC/DC converter connected in parallel, wherein the first and second AC/DC converters are operatively configured to rectify the first AC output current into a second direct current, and

wherein the second AC/DC converter and the high power switch are geometrically integrated into a modularly-configured combination charging unit, while the first AC/DC converter is disposed externally from the modularly-configured combination charging unit.

10. The electric vehicle according to claim 9, further comprising:

a DC/AC converter coupled upstream of the electric machine, the second direct current being supplied to the electric machine via the DC/AC converter or being supplied to the electric machine and simultaneously to the rechargeable battery for charging.

11. The electric vehicle according to claim 9, wherein the first and second AC/DC converters are operatively configured to rectify the second AC output current into a third direct current, the third direct current being supplied to charge the rechargeable battery.

12. The electric vehicle according to claim 9, wherein the first and second AC/DC converters are, respectively, configured for a maximum input power of at least 230 volts×

16 amperes.

13. The electric vehicle according to claim 9, wherein the high power switch is a DC contactor.

14. The electric vehicle according to claim 13, further comprising at least one control device operatively configured to control the combination charging unit, the first AC/DC converter, the first plug-in charging device and the second plug-in charging device.

15. The electric vehicle according to claim 9, wherein the parallel coupling of the first and second AC/DC converters occurs outside of the combination charging unit.

17. The electric vehicle according to claim 9, wherein the combination charging unit, comprising the second AC/DC converter and the high power switch, is disposed in a housing that is removeably distinct from the vehicle.

19. The system electric vehicle to claim 17, the second AC/DC converter is integrated into the combination charging unit so as to be mechanically disconnectable therefrom, and removable from the housing.