Combined charger and power converter

• US 10,720,787 B2
• Filed: 07/24/2018
• Issued: 07/21/2020
• Est. Priority Date: 07/26/2017
• Status: Active Grant

• Current Assignee: Delta-Q Technologies Corp. (ZAPI S.p.A.)
• Original Assignee: Delta-Q Technologies Corp. (ZAPI S.p.A.)
• Inventors: Dohmeier, Nicholas Adam, MacCallum, Haakon, Botting, Christopher Jon
• Primary Examiner(s): Deberadinis, Robert L
• Application Number:
  US16/044,134
• Publication Number:
  US 20190036366A1
• Time in Patent Office: 728 Days
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 7/00032 characterised by data exchange
• 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 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/345 using capacitors as storage or buffering devices
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

An apparatus and method employs a rectifier, switches, and power converter that comprises a first stage, a second stage and a direct current (DC) bus between the first and second stages, to: in a first state supply rectified DC current to the first stage and a voltage adjusted current from the second stage to a load, for example a power storage device (e.g., secondary battery, ultra-capacitor(s)) at a relatively high voltage (e.g., 48 V for traction motor), and in a second state supply DC current to the first stage from the power storage device and supply a voltage adjusted current from the second stage, for example to a lower voltage DC bus or load (e.g., 12 V). The rectifier can, for example, receive grid or mains AC power.

Claims

1. An apparatus comprising:

a set of alternating current (AC) nodes;

a first and a second set of direct current (DC) nodes;

a power converter comprising a first stage, a second stage, and an intermediate DC voltage bus electrically coupled between the first and the second stage, the power converter operable to adjust a voltage level of a current supplied thereto;

a first set of switches, the switches of the first set of switches having a first state and at least a second state, the first set of switches operable to switch between electrically coupling the first stage of the power converter to the set of AC nodes in the first state and electrically coupling the first stage of the power converter to the first set of DC nodes in the second state;

a second set of switches, the switches of the second set of switches having a first state and at least a second state, the second set of switches operable to switch between electrically coupling the second stage of the power converter to the first set of DC nodes in the first state and electrically coupling the second stage of the power converter to the second set of DC nodes in the second state; and

a controller communicatively coupled to control the switches of the first and the second set of switches to place the switches of both the first and the second set of switches in the respective first states concurrently, and to place the switches of both the first and the second set of switches in the respective second states concurrently.

2. The apparatus of claim 1, further comprising:

a rectifier electrically coupled to the set of AC nodes, the rectifier operable to convert an alternating current to a direct current, wherein the first set of switches is operable to electrically couple the first stage of the power converter to the rectifier in the first state.

3. The apparatus of claim 1, wherein the controller is communicatively coupled to control the switches of the first and the second set of switches to place the switches of both the first and the second set of switches in the respective first states simultaneously, and to place the switches of both the first and the second set of switches in the respective second states simultaneously.

4. The apparatus of claim 1, wherein the controller is communicatively coupled to control the switches of the first and the second set of switches to place the switches of the first set of switches in the respective first state simultaneously with one another, and to place the switches of the first set of switches in the respective second state simultaneously with one another, and/or to place the switches of the second set of switches in the respective first state simultaneously with one another, and to place the switches of the second set of switches in the respective second state simultaneously with one another.

5. The apparatus of claim 1, further comprising:

at least one of a first set of battery cells or a first set of super-capacitors having a first nominal DC voltage, the at least one of the first set of battery cells or the first set of super-capacitors electrically coupled to the first set of DC nodes.

6. The apparatus of claim 5 wherein the at least one of the first set of battery cells or the first set of super-capacitors comprises a traction power pack that is operable to supply current to a traction motor of an electric vehicle.

7. The apparatus of claim 5 wherein, when the switches of the first and the second sets of switches are in the respective first states, the power converter is operable to supply a current at the first nominal DC voltage to charge the at least one of the first set of battery cells or the first set of super-capacitors.

8. The apparatus of claim 1, further comprising:

a low-voltage DC subsystem having a second nominal DC voltage level, the low-voltage DC subsystem electrically coupled to the second set of DC nodes.

9. The apparatus of claim 8 wherein, when the switches of the first and the second sets of switches are in the respective second states, the power converter is operable to supply a current at the second DC nominal voltage level to the low-voltage DC subsystem.

10. The apparatus of claim 9 wherein the second nominal DC voltage is lower than the first nominal DC voltage.

11. The apparatus of claim 10 wherein the low-voltage subsystem is a low-voltage subsystem of an electric vehicle.

12. The apparatus of claim 10 wherein the low-voltage subsystem comprises at least one of a second set of battery cells or a second set of super-capacitors.

13. The apparatus of claim 1, further comprising an AC voltage source electrically coupled to the set of AC nodes.

14. The apparatus of claim 13 wherein the AC voltage source is a 120 V/60 Hz mains supply.

15. The apparatus of claim 13 wherein the AC voltage source is a single-phase AC voltage source.

16. The apparatus of claim 2 wherein the rectifier is operable to receive universal AC input.

17. The apparatus of claim 1 wherein at least one of the first or the second set of switches includes a respective in-rush limiting circuit.

18. The apparatus of claim 1 wherein at least one of the first or the second set of switches includes a protective circuit responsive to an electrical abnormality.

19. The apparatus of claim 1 wherein the intermediate DC bus voltage is selectable in response to a magnitude of a desired output voltage of the power converter.

20. The apparatus of claim 1 wherein the power converter comprises an isolated DC/DC converter.

21. The apparatus of claim 1 wherein the power converter comprises an LLC resonant DC/DC converter.

22. The apparatus of claim 1 wherein at least one switch of the first or the second set of switches includes a relay.

23. The apparatus of claim 1 wherein at least one of the first or the second set of switches includes a double pole double throw relay.

24. The apparatus of claim 1, further comprising an auxiliary housekeeping supply, the auxiliary housekeeping supply powered by the intermediate DC bus.

25. The apparatus of claim 24, wherein the auxiliary housekeeping supply is operable to provide a low power bias to the low-voltage subsystem when the switches of the first and the second sets of switches are in the respective first states.

26. A method of operation of a system comprising a first set of switches, a second set of switches, and a power converter, the power converter having a first stage, a second stage and an intermediate DC bus electrically coupled between the first and the second stages, the method comprising:

selectively charging at least one of a first set of battery cells or a first set of super-capacitors by;

coupling a voltage at a first nominal voltage level to the first stage of the power converter; and

coupling a DC voltage at a second nominal voltage level from the second stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors; and

selectively powering a low-voltage DC subsystem by;

coupling a DC voltage at the second nominal voltage level from the at least one of a first set of battery cells or a first set of super-capacitors to the first stage of the power converter; and

coupling a DC voltage at a third nominal voltage level from the second stage of the power converter to the low-voltage DC subsystem.

27. The method of claim 26, the system further comprising a rectifier, wherein selectively charging at least one of a first set of battery cells or a first set of super-capacitors includes rectifying an alternating current (AC) voltage by the rectifier to generate a DC voltage at the first nominal voltage level.

28. The method of claim 27, further comprising:

receiving the AC voltage by the rectifier from an AC voltage source.

29. The method of claim 27 wherein coupling a DC voltage at the first nominal voltage level to the first stage of the power converter and coupling a DC voltage at a second nominal voltage level from the second stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors comprises:

operating the switches of the first set of switches to electrically couple the first stage of the power converter to the rectifier, and operating the switches of the second set of switches to electrically couple the second stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors.

30. The method of claim 26 wherein coupling a DC voltage at a third nominal voltage level from the second stage of the power converter to the low-voltage subsystem includes coupling the DC voltage at the third nominal voltage level to at least one of a second set of battery cells or a second set of super-capacitors electrically coupled to the low-voltage subsystem.

31. The method of claim 26, wherein the third nominal voltage level is different from the associated nominal voltage level of the at least one of a first set of battery cells or a first set of super-capacitors.

32. The method of claim 26, further comprising:

adjusting an intermediate DC bus voltage of the intermediate DC bus.

33. The method of claim 32, wherein adjusting an intermediate DC bus voltage of the intermediate DC bus may include adjusting an intermediate bus voltage of the intermediate DC bus to charge the at least one of a second set of battery cells or a second set of super-capacitors.

34. The method of claim 26 wherein coupling the voltage at the first nominal voltage level to the first stage of the power converter and coupling a DC voltage at a second nominal voltage level from the second stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors comprises:

operating the switches of the first set of switches to electrically couple the first stage of the power converter to an AC power source, and operating the switches of the second set of switches to electrically couple the second stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors.

35. The method of claim 26 wherein coupling a DC voltage at the second nominal voltage level from the at least one of a first set of battery cells or a first set of super-capacitors to the first stage of the power converter and coupling a DC voltage at a third nominal voltage level from the second stage of the power converter to the low-voltage subsystem comprises:

operating the switches of the first set of switches to electrical couple the first stage of the power converter to the at least one of a first set of battery cells or a first set of super-capacitors, and operating the switches of the second set of switches electrically couple the second stage of the power converter to the low-voltage subsystem.

36. An apparatus comprising:

a set of alternating current (AC) nodes;

a first and a second set of direct current (DC) nodes;

a power converter comprising a first stage, a second stage, and an intermediate DC voltage bus electrically coupled between the first and the second stage, the power converter operable to adjust a voltage level of a current supplied thereto;

a first set of switches, the switches of the first set of switches having a first state and at least a second state, the first set of switches operable to switch between electrically coupling the first stage of the power converter to the set of AC nodes in the first state and electrically coupling the first stage of the power converter to the first set of DC nodes in the second state; and

a controller communicatively coupled to control the switches of the first set of switches to place the switches of the first set of switches in the respective first state concurrently, and to place the switches of the first set of switches in the respective second state concurrently.

37. The apparatus of claim 36, further comprising an auxiliary housekeeping supply, the auxiliary housekeeping supply powered by the intermediate DC bus.