Charge transfer system

• US 9,783,070 B2
• Filed: 12/05/2014
• Issued: 10/10/2017
• Est. Priority Date: 02/14/2014
• Status: Active Grant

• Current Assignee: Jabil Inc.
• Original Assignee: Jabil Circuit Incorporated (Jabil Inc.)
• Inventors: Danner, Jeffrey David
• Primary Examiner(s): Johnson, Ryan
• Application Number:
  US14/562,399
• Publication Number:
  US 20150231978A1
• Time in Patent Office: 1,040 Days
• CPC Class Codes: B60L 2220/52 Clutch motors
• CPC Class Codes: B60L 2220/54 Windings for different functions
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A charge transfer system includes an on-board vehicle motor system and a plug in supply. The on-board vehicle motor system includes a first motor including a plurality of stator windings, a second motor including a plurality of stator windings, a first inverter having a plurality of switch legs, a second inverter having a plurality of switch legs, a controller, and an on-board power supply. The plug-in supply is connected between at least one switch leg of the first inverter and at least one switch leg of the second inverter. The controller modulates the switch legs of the first and second inverters such that electric current flows through at least one stator winding of the first or second motor to charge the on-board power supply. The current flow can also alternate in phase with plug-in supply polarity to produce a stable stator flux vector angle preventing motor rotation during charge transfer.

Claims

1. A charge transfer system, comprising:

a plug-in power supply electrically connected between at least one of a first plurality of switch legs of a first inverter and at least one of a second plurality of switch legs of a second inverter; and

a controller operatively coupled to the first inverter and the second inverter,

wherein the controller selectively modulates at least one of the first plurality of switch legs of the first inverter or at least one of the second plurality of switch legs of the second inverter such that electric current flows from the plug-in power supply through at least one of a first plurality of stator windings of a first motor or at least one of a second plurality of stator windings of a second motor to charge an on-board vehicle power supply, and wherein the controller further selectively modulates the plurality of switch legs of the first inverter that are not directly connected to the plug-in power supply and the plurality of switch legs of the second inverter that are not directly connected to the plug-in power supply to reduce common mode noise between the plug-in supply and on-board vehicle power supply.

2. The charge transfer system of claim 1, wherein the controller selectively modulates switch legs such that electric current flow alternates between the at least one of the first plurality of stator windings of the first motor to charge the on-board vehicle power supply during a first plug-in supply voltage polarity state and the at least one of the second plurality of stator windings of the second motor to charge the on-board vehicle power supply during a second plug-in supply voltage polarity state.

3. The charge transfer system of claim 2, wherein the selective modulation produces a unidirectional magnetizing current within the first motor and the second motor to produce a stationary zero torque rotor angle.

4. The charge transfer system of claim 1, wherein the controller interleaves the switch leg modulation to reduce the current ripple on the plug-in supply.

5. The charge transfer system of claim 1, wherein selective modulating the at least one of the first plurality of switch legs of the first inverter and/or at least one of the second plurality of switch legs of the second inverter produces a unity power factor.

6. The charge transfer system of claim 1, wherein selective modulating the at least one of the first plurality of switch legs of the first inverter and/or at least one of the second plurality of switch legs of the second inverter occurs within a frequency range between 10-20 kilohertz.

7. The charge transfer system of claim 1, wherein the plug-in supply further comprises an electromagnetic interference filter.

8. The charge transfer system of claim 1, wherein the first motor and second motor are permanent magnet synchronous motors.

9. The charge transfer system of claim 1, wherein the first motor and second motor are AC induction motors.

10. The charge transfer system of claim 1, wherein the first motor and second motor are switched reluctance motors.

11. The charge transfer system of claim 1, wherein the first plurality of stator windings of the first motor and the second plurality of stator windings of the second motor are configured in a star connection.

12. The charge transfer system of claim 1, wherein the controller selectively modulates at least one of the plurality of switch legs of the first inverter and of the plurality of switch legs of the second inverter such that electric current flows to the plug-in supply through at least one of the plurality of stator windings of the first motor or at least one of the plurality of stator windings of the second motor to discharge the on-board vehicle power supply.

13. The charge transfer system of claim 1, wherein the controller selectively modulates at least one of the first plurality of switch legs of the first inverter and at least one of the second plurality of switch legs of the second inverter.

14. A charge transfer system including a plug-in power supply, a first plurality of switch legs of a first inverter, a second plurality of switch legs of a second inverter, a first plurality of stator windings of a first motor, a second plurality of stator windings of a second motor and on-board vehicle power supply, comprising:

a controller adapted to operatively couple to the first inverter and the second inverter; and

the controller adapted to selectively modulate at least one of the first plurality of switch legs of the first inverter or at least one of the second plurality of switch legs of the second inverter such that electric current flows from the plug-in power supply through at least one of the first plurality of stator windings of the first motor or at least one of the second plurality of stator windings of the second motor to charge the on-board vehicle power supply, and wherein the controller further selectively modulates the plurality of switch legs of the first inverter that are not directly connected to the plug-in power supply and the plurality of switch legs of the second inverter that are not directly connected to the plug-in power supply to reduce common mode noise between the plug-in supply and on-board vehicle power supply, and

wherein the plug-in power supply is electrically connected between at least one of the first plurality of switch legs of the first inverter and at least one of the second plurality of switch legs of the second inverter.

15. The charge transfer system of claim 14, wherein the controller selectively modulates switch legs such that electric current flow alternates between the at least one of the first plurality of stator windings of the first motor to charge the on-board vehicle power supply during a first plug-in supply voltage polarity state and the at least one of the second plurality of stator windings of the second motor to charge the on-board vehicle power supply during a second plug-in supply voltage polarity state.

16. A non-transitory computer-usable medium having instructions recorded thereon that, if executed by a controller, cause the controller, in cooperation with a plug-in power supply, a first plurality of switch legs of a first inverter, a second plurality of switch legs of a second inverter, a first plurality of stator windings of a first motor, a second plurality of stator windings of a second motor and on-board vehicle power supply, to perform a method comprising:

selectively modulating at least one of the first plurality of switch legs of the first inverter or at least one of the second plurality of switch legs of the second inverter such that electric current flows from the plug-in power supply through at least one of the first plurality of stator windings of the first motor or at least one of the second plurality of stator windings of the second motor to charge the on-board vehicle power supply, wherein the controller is operatively coupled to the first inverter and the second inverter, and wherein the plug-in power supply is electrically connected between at least one of the first plurality of switch legs of the first inverter and at least one of the second plurality of switch legs of the second inverter, and wherein the controller further selectively modulates the plurality of switch legs of the first inverter that are not directly connected to the plug-in power supply and the plurality of switch legs of the second inverter that are not directly connected to the plug-in power supply to reduce common mode noise between the plug-in supply and on-board vehicle power supply.