Dual-charger system

• US RE45,208 E1
• Filed: 02/14/2013
• Issued: 10/28/2014
• Est. Priority Date: 08/16/2010
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Humphrey, Stephen, O'Brien, Thomas, Sweet, Benjamin D., Beehler, Ryan, Hampo, Richard
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US13/766,880
• Time in Patent Office: 621 Days
• Field of Search: 320/103, 320/104, 320/107, 320/114, 320/115, 320/138
• US Class Current: 320/138
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/0084 relating to control modules
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 53/60 Monitoring or controlling charging stations
• CPC Class Codes: Y02T 10/7005 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 90/121 by conductive energy transmission
• CPC Class Codes: Y02T 90/128 Energy exchange control or determination
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/163 Information or communication technologies related to charging of electric vehicle

Abstract

A dual-charger system operable to facilitate charging a battery with energy regulated by two chargers connected in parallel to the battery where one charger operates according to a voltage regulation mode and the other of the two chargers operates according to a current regulation mode.

Claims

1. A dual-charger system for use in charging a battery within a vehicle using energy provided from an AC source outside of the vehicle, the system comprising:

a first charger being operably connected to the AC source, the first charger being operable to charge the battery with a first DC voltage and a first DC current; and

a second charger being operably connected to the AC source and in parallel with the first charger, the second charger being operable to charge the battery with a second DC voltage and a second DC current;

wherein the chargers are in a connection arrangement such that the chargers appear to a vehicle controller as being a single charger;

wherein the first charger is further operable to vary the first DC voltage as a function of a difference between a net voltage set by a combination of the first and second DC voltages and a charging voltage desired for charging the battery.

2. The system of claim 1 wherein the first charger is further operable to vary the first DC voltage as a function of a difference between a net voltage set by a combination of the first and second DC voltages and a charging voltage desired for charging the battery.

3. The system of claim 2 1 wherein the first charger is further operable to decrease the first DC voltage when the net voltage increases and to increase the first DC voltage when the net decreases, wherein the first charger is further operable to increase and decrease the first DC voltage in proportion to a difference between the net voltage and the charging voltage.

4. The system of claim 1 wherein the second charger is further operable to vary the second DC current as a function of difference between a net current set by a combination of the first and second DC currents and a charging current desired for charging the battery.

5. The system of claim 4 wherein the second charger is further operable to decrease the second DC current when the net current increases and to increase the second DC current when the net current decreases, wherein the second charger is further operable to increase and decrease the second DC current in proportion to a difference between the net current and the charging current.

6. The system of claim 1 wherein a charging voltage and a charging current is desired for charging the battery and wherein:

(i) a first voltage limit of the first charger is set to a voltage approximately equal to the charging voltage, the first charger being prevented from outputting the first DC voltage above the first voltage limit;

(ii) a second voltage limit of the second charger is set to a voltage greater than the charging voltage, the second charger being prevented from outputting the second DC voltage above the second voltage limit;

(iii) a first current limit of the first charger is set to a current greater than half of the charging current, the first charger being prevented from outputting the first DC current above the first current limit; and

(iv) a second current limit of the second charger is set to a current no greater than half of the charging current, the second charger being prevented from outputting the second DC current above the second current limit.

7. The system of claim 1 wherein each of the first and second chargers connect to a positive cable connected to a positive pole of the battery and a negative cable connected to a negative pole of the battery such that the first charger and second charger are in parallel.

8. The system of claim 1 wherein the first and second chargers are each further operable to receive energy from the AC source through electric vehicle supply equipment (EVSE).

9. A method of regulating output of first and second chargers that are connected in parallel with one another, the first and the second chargers being operable to charge a battery included within a vehicle, the method comprising:

determining a charging voltage and a charging current needed to charge the battery;

in the event both of the first and second charger are required to provide the charging voltage and the charging current, performing the operations of;

(i) commanding the first charger to output a first voltage that is generally equal to the charging voltage desired for charging the battery;

(ii) commanding the second charger to output a second voltage that is greater than the charging voltage;

(iii) commanding the first charger to output a first current; and

(iv) commanding the second charger to output a second current that is generally equal to a difference between the first current and the charging current.

10. The method of claim 9 further comprising:

(i) commanding only the first charger to decrease the first voltage by an amount proportional to the first amount in the event the combined first and second voltage is greater than the charging voltage by a first amount; and

(ii) commanding only the first charger to increase the first voltage by an amount proportional to the second amount in the event the combined first and second voltage is less than the charging voltage by a second amount.

11. The method of claim 9 further comprising

(i) commanding only the second charger to decrease the second current by an amount proportional to the first amount in the event the combined first and second current is greater than the charging current by a first amount;

and

(ii) commanding only the second charger to increase the second current by an amount proportional to the second amount in the event the combined first and second current is less than the charging current by a second amount.

12. The method of claim 9 further comprising commanding the first charger to provide the first current equal to generally one half of the charging current.

13. The method of claim 9 further comprising commanding a randomly selected one of the first and second chargers to provide the charging voltage and current in the event a single one of the first and second chargers is capable of providing the charging voltage and current.

14. A dual-charger system for use in charging a battery via energy from an a source, the system comprising:

a first charger being operably connected to the source, the first charger being operable to charge the battery with a first voltage and a first current; and

a second charger operably connected to the source in parallel with the first charger, the second charger being operable to charge the battery with a second voltage and a second current;

wherein one of the chargers operates according to a voltage regulation mode and the other one of the chargers operates according to a current regulation mode.

15. The system of claim 14 wherein the second charger is instructed to output the second voltage to be greater than the first voltage.

16. The system of claim 14 wherein the first charger is instructed to output the first current to be no more than half of a charging current desired for charging the battery.

17. The system of claim 16 wherein the second charger is instructed to output the second current to be approximately equal to a difference between the first current and the charging current.

18. The system of claim 15 wherein one of the first and second chargers is deactivated in the event the other one of the first and second chargers is able to provide voltage and current sufficient to meet a charging voltage and charging current desired for charging the battery.

19. The system of claim 15 wherein each of the first and second chargers are within a vehicle and commonly connect to a receptacle with the vehicle operable to receive energy through electric vehicle supply equipment (EVSE).

20. The system of claim 19 wherein the first and second chargers are operable to convert AC energy to DC energy such that each of the first and second voltages and first and second currents are DC.