Controlling batteries for electric bus

• US 10,270,265 B2
• Filed: 07/17/2017
• Issued: 04/23/2019
• Est. Priority Date: 03/26/2014
• Status: Active Grant

• Current Assignee: New Flyer Industries Canada ULC (NFI Group, Inc.)
• Original Assignee: New Fryer Industries Canada ULC
• Inventors: Owen, Robert Brydon Thomas, Naylor, David Glen
• Primary Examiner(s): Berhanu, Samuel
• Application Number:
  US15/651,137
• Publication Number:
  US 20170317508A1
• Time in Patent Office: 645 Days
• Field of Search: 320124, 320125, 320128, 320135
• CPC Class Codes: B60L 1/06 using only one supply
• CPC Class Codes: B60L 1/14 to electric lighting circuits
• CPC Class Codes: B60L 2200/18 Buses
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/486 Operating parameters
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2240/62 Vehicle position
• CPC Class Codes: B60L 2240/80 Time limits
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• 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 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• 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 53/30 : Constructional details of charging stations
• CPC Class Codes: B60L 53/32 : by charging in short intervals along the itinerary, e.g. during short stops
• CPC Class Codes: B60L 53/65 : involving identification of vehicles or their battery types
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: H02J 2310/48 : for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/00041 : in response to measured battery parameters, e.g. voltage, current or temperature profile
• CPC Class Codes: H02J 7/00047 : with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0013 : acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0014 : Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/0049 : Detection of fully charged condition
• 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
• 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 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

An onboard charging system for an electric vehicle is configured to communicate with a power supply through exchange of control signals on a power supply line by modulating a charging current being supplied to the charging system. The charging system is capable of communicating fault and battery parameter data to the power supply, as well as a requested charging current used to regulate the power supply output. The power supply may convert high voltage AC power into a controllable DC output supplied directly to the electric vehicle, thereby providing a convenient means for the vehicle to initiate charging during operations. Connection between the electric vehicle and the power supply may be effected using an extendible and retractable electrical connection, such as a mechanical pantograph.

Claims

1. A method, performed by a charge controller of a passenger bus, of charging a plurality of energy storage devices of the passenger bus, comprising:

on engagement of a charge control system of the passenger bus with a charge station, executing a pre-charge sequence to confirm that at least one of the passenger bus and an energy storage system of the passenger bus is in a ready state for charging to occur;

supplying a charging current to a first grouping of energy storage devices of the energy storage system;

conditioned upon determining that a voltage of at least one energy storage device of a second grouping of energy storage devices of the energy storage system is less than a specified maximum difference greater than a group voltage of one or more energy storage devices of the first grouping, supplying a charging current to the at least one energy storage device of the second grouping; and

upon receipt of a signal representing at least one of a charge termination command generated by an operator of the passenger bus, a fault indication, and a charge-complete condition associated with one or more of the energy storage devices, terminating supply of a charge current to at least one energy storage device of the energy storage system.

2. The method of claim 1, wherein the a plurality of the energy storage devices in the first grouping are connected in parallel to the power supply line.

3. The method of claim 2, wherein the at least one energy storage device of the second grouping is connected to the power supply line in parallel with the one or more energy storage devices in the first grouping.

4. The method of claim 1, wherein the at least one energy storage device of the second grouping has a lowest voltage among the one or more energy storage devices in the second grouping.

5. The method of claim 4, further comprising:

measuring a voltage of each energy storage device in the second grouping; and

determining the lowest voltage energy device in the second grouping based on comparison of the measured voltages.

6. The method of claim 5, further comprising:

determining when to connect the selected energy storage device from the second grouping to the power supply line based on comparison of the monitored group voltage and the measured voltage of the selected energy storage device.

12. The method of claim 1, wherein engagement of the charge control system of the passenger bus with the charge station comprises using at least one of a proximity-sensing device and a position-sensing device to align an electrical connection on the bus with an interface of the charge station.

13. The method of claim 1, wherein execution of the pre-charge sequence comprises confirming that at least one load has been disconnected from the energy storage system.

14. The method of claim 1, wherein execution of the pre-charge sequence comprises confirming that applying a charge current will not cause the passenger bus to drive forward or backward.

24. The method of claim 1, wherein execution of the pre-charge sequence comprises confirming that no fault condition exists in the passenger bus.

25. The method of claim 1, wherein execution of the pre-charge sequence comprises confirming that no fault condition exists in the energy storage system.

7. A method, performed by a charge controller of a passenger bus, of charging a plurality of energy storage devices of the passenger bus, comprising:

on engagement of a charge control system of the passenger bus with a charge station, connecting an initial grouping of the energy storage devices to a power supply line, the initial grouping comprising one or more energy storage devices determined to have respective voltages within a specified maximum difference of each other;

supplying the initial grouping of energy storage devices with a charging current on the power supply line;

connecting a remainder of the energy storage devices not included in the initial grouping to the power supply line by monitoring a group voltage of the one or more energy storage devices currently connected to the power supply line while the charging current is supplied to the power supply line and, for each respective energy storage device in the remainder, connecting the respective energy storage device to the power supply line when it is determined that the monitored group voltage of the one or more energy storage devices currently connected to the power supply line and the voltage of the respective energy storage device in the remainder are within a specified maximum difference of each other; and

upon receipt of a signal representing at least one of a charge termination command generated by an operator of the passenger bus, a faint indication, and a charge-complete condition associated with one or more of the energy storage devices, terminating supply of a charge current to at least one energy storage device of the energy storage system.

8. The method of claim 7, wherein the one or more energy storage devices in the initial grouping are connected in parallel to the power supply line.

9. The method of claim 8, wherein each respective energy storage device in the remainder is connected to the power supply line in parallel with the one or more energy storage devices currently connected to the power supply line.

10. The method of claim 7, further comprising:

measuring an initial voltage of each of the plurality of energy storage devices; and

determining the initial grouping of the energy storage devices based on comparison of the measured initial voltages.

11. The method of claim 10, further comprising:

determining when to connect the remainder of the plurality of energy storage devices to the power supply line, for each respective energy storage device in the remainder, based on comparison of the monitored group voltage and the measured initial voltage of the respective energy storage device in the remainder.

15. The method of claim 7, wherein engagement of the charge control system of the passenger bus with the charge station comprises using at least one of a proximity-sensing device and a position-sensing device to align an electrical connection on the bus with an interface of the charge station.

16. The method of claim 7, wherein execution of the pre-charge sequence comprises confirming that at least one load has been disconnected from the energy storage system.

17. The method of claim 7, wherein execution of the pre-charge sequence comprises confirming that applying a charge current will not cause the passenger bus to drive forward or backward.

18. A passenger bus having a charge control system comprising a plurality of energy storage devices and a charge controller, the charge controller configured to:

connect an initial grouping of the plurality of energy storage devices to a power supply line, the initial grouping comprising a plurality of energy storage devices determined to have respective voltages within a specified maximum difference of each other;

supply the initial grouping of energy storage devices with a charging current on the power supply line;

connect a plurality the energy storage devices not included in the initial grouping to the power supply line by monitoring a group voltage of the one or more energy storage devices currently connected to the power supply line while the charging current is supplied to the power supply line and, for each respective energy storage device in the remainder, connecting the respective energy storage device to the power supply line when it is determined that the monitored group voltage of the one or more energy storage devices currently connected to the power supply line and the voltage of the respective energy storage device in the remainder are within a specified maximum difference of each other; and

upon receipt of a signal representing at least one of a charge termination command generated by an operator of the passenger bus, a fault indication, and a charge-complete condition associated with one or more of the energy storage devices, terminating supply of a charge current to at least one energy storage device of the energy storage system.

19. The passenger bus of claim 18, comprising at least one of a proximity device and a location-sensing device, wherein engagement of the charge control system of the passenger bus with the charge station comprises using at least one of a proximity-sensing device and a position-sensing device to align an electrical connection on the bus with an interface of the charge station.

20. The passenger bus of claim 18, wherein connecting the initial grouping of the plurality of energy storage devices to a power supply line comprises confirming that at least one load has been disconnected from the energy storage system.

21. The passenger bus of claim 18, wherein connecting the initial grouping of the plurality of energy storage devices to a power supply line comprises confirming that applying a charge current will not cause the passenger bus to drive forward or backward.

22. The passenger bus of claim 18, wherein connecting the initial grouping of the plurality of energy storage devices to a power supply line comprises confirming that no fault condition exists in the passenger bus.

23. The passenger bus of claim 18, wherein connecting the initial grouping of the plurality of energy storage devices to a power supply line comprises confirming that no fault condition exists in the energy storage system.