Modular extra low voltage electric vehicle power system

• US 10,554,164 B2
• Filed: 11/01/2016
• Issued: 02/04/2020
• Est. Priority Date: 11/01/2016
• Status: Active Grant

• Current Assignee: Sungrow Power Supply Co., Ltd.
• Original Assignee: Sungrow Power Supply Co., Ltd.
• Inventors: Ilic, Milan, Maksimovic, Dragan, Nuotio, Mika
• Primary Examiner(s): Masih, Karen
• Application Number:
  US15/340,824
• Publication Number:
  US 20180123496A1
• Time in Patent Office: 1,190 Days
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/526 Operating parameters
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• 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 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02P 25/22 Multiple windings; Windings for more than three phases
• CPC Class Codes: H02P 27/08 with pulse width modulation
• 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 10/72 : Electric energy management in electromobility
• 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

Abstract

In some aspects, an electric vehicle power system may comprise two or more electrically connected power modules connected to a system communication bus. Each power module may comprise a rechargeable battery electrically connected to a DC bus, an inverter circuit electrically connected to the DC bus, and at least one of a single-phase rectifier circuit electrically connected to the DC bus or a multi-phase rectifier circuit electrically connected to the DC bus. A local controller configured to send control signals may be connected to the rechargeable battery, the inverter circuit, and the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit. The single-phase rectifier circuit may be configured to convert a single-phase AC power signal into the DC voltage of the DC bus. The multi-phase rectifier circuit may be configured to convert a multi-phase AC power signal into the DC voltage of the DC bus.

Claims

1. An electric vehicle power system comprising:

a plurality of electrically connected power modules connected to a system communication bus and configured to be activated to deliver electrical power to an electric motor, each power module comprising;

a rechargeable battery module electrically connected to a DC bus;

an inverter circuit electrically connected to the DC bus, wherein the inverter circuit is configured to convert a DC voltage of the DC bus into an AC power signal, and wherein the inverter circuit is configured to be connected to an electric motor;

at least one of;

a single-phase rectifier circuit electrically connected to the DC bus, the single-phase rectifier circuit configured to convert a single-phase AC power signal into the DC voltage of the DC bus;

or

a multi-phase rectifier circuit electrically connected to the DC bus, the multi-phase rectifier circuit configured to convert a multi-phase AC power signal into the DC voltage of the DC bus; and

a local controller connected to the rechargeable battery module, the inverter circuit, and the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit, the local controller configured to generate one or more control signals and determine whether an output power of one of the plurality of electrically connected power modules exceeds a threshold power level;

wherein another power module of the plurality of electrically connected power modules is activated to deliver electrical power to the electric motor in response to determining that the output power of one of the plurality of electrically connected power modules exceeds the threshold power level; and

wherein the plurality of power modules are connected in parallel to at least one electric motor.

2. The system of claim 1, wherein each power module further comprises a DC to DC converter circuit electrically connected to the DC bus and to an auxiliary power bus.

3. The system of claim 1, wherein, for each of the plurality of power modules, the local controller is configured to detect at least one of:

the DC voltage of the DC bus, an input voltage of the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit, an input current of the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit, an output current of the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit, an input current or voltage of the inverter circuit, and an output current or voltage of the inverter circuit.

4. The system of claim 1, wherein, for each of the plurality of power modules, the local controller is configured to transmit a control signal to the inverter circuit in order to control a power output of the inverter circuit.

5. The system of claim 4, wherein the control signal is a pulse-width modulation signal.

6. The system of claim 1, wherein, for each of the plurality of power modules, the local controller is configured to transmit a control signal to the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit to control an input power of the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit.

7. The system of claim 1, wherein the DC bus voltage of each of the plurality of power modules is below 50 volts.

8. The system of claim 1, wherein, for each of the plurality of power modules, the local controller is configured to receive control signals from a master controller, the control signals configured to modify at least one of an output power of the at least one of the single-phase rectifier circuit or the multi-phase rectifier circuit and an output power of the inverter circuit.

9. The system of claim 1, wherein the master controller is a local controller of one of the plurality of power modules.

10. The system of claim 1, wherein the single-phase AC power signal originates from one of a 120 volt AC wall outlet or a 240 volt AC wall outlet.

11. A method for providing power for a vehicle, the method comprising:

receiving, from a user at a master controller, a throttle input;

generating, based on the throttle input, a throttle control signal;

transmitting, using a system communication bus, the throttle control signal to a plurality of local controllers, each local controller located within one of a plurality of electrically connected power modules, each power module comprising;

a rechargeable battery module electrically connected to a DC bus;

an inverter circuit electrically connected to the DC bus, wherein the inverter circuit is configured to convert a DC voltage of the DC bus into an AC power signal, and wherein the inverter circuit is configured to be connected to an electric motor;

activating a first power module of the plurality of power modules to deliver electrical power to the electric motor based on the throttle control signal;

detecting whether an output power of the first power module exceeds a threshold power level;

in response to detecting that the output power of the first power module exceeds the threshold power level, activating a second power module of the plurality of electrically connected power modules to deliver electrical power to the electric motor based on the throttle control signal.

12. The method of claim 11, wherein the throttle input is generated by an accelerator pedal depressed by the user.

13. The method of claim 11, wherein the throttle control signal is a pulse width modulation signal with a duty cycle between 0 and 100% proportional to the ratio of the throttle input to a maximum throttle input.

14. The method of claim 11, wherein the throttle control signal adjusts a switching frequency of the inverter circuit of at least one of the first power module and the second power module.

15. The method of claim 11, further comprising generating a second throttle control signal and transmitting the second throttle control signal to the second power module.

16. The method of claim 11, wherein the master controller is the local controller of one of the plurality of power modules.

17. The method of claim 11, wherein the threshold power level is less than 100% of a maximum output power of the first power module.

18. The method of claim 11, wherein the DC bus voltage of each of the plurality of power modules is below 50 volts.

19. The method of claim 11, wherein the throttle control signal is a DC voltage signal between 0 volts and a maximum control voltage level.

20. The method of claim 11, further comprising, in response to detecting that the output power of the first of the plurality of power modules exceeds the threshold power level, transmitting a control signal to the first power module to reduce the output power of the first power module.