POWER SOURCE SYSTEM FOR ELECTRIC POWERED VEHICLE AND CONTROL METHOD THEREFOR

• US 20120123625A1
• Filed: 08/07/2009
• Published: 05/17/2012
• Est. Priority Date: 08/07/2009
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Masuda, Tomokazu, Ueo, Daisuke
• Granted Patent: US 8,478,469 B2
• Time in Patent Office: Days
• US Class Current: 701/22
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• 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

Abstract

At the time of external charging, an external charging relay is turned on, and a system main relay is turned off. Therefore, a main battery can be charged by electric power from an external power source, without applying an output voltage of the main battery to a PCU. At the time of external charging, basically, a power supply voltage for an auxiliary system (low voltage system) is generated by a sub DC/DC converter of a small capacity, while a main DC/DC converter of a large capacity used when vehicle is running is stopped. Only when the output of sub DC/DC converter is insufficient to cover the power consumption by the auxiliary system, an ECU operates the main DC/DC converter. Therefore, ECU and auxiliary load group can be operated reliably while efficiency of external charging is improved.

Claims

1. A power source system for an electric powered vehicle chargeable by an external power source outside of the vehicle, comprising:

rechargeable main power storage device and sub power storage device;

a charger for converting electric power supplied from said external power source to an electric power for charging said main power storage device, at a time of external charging for charging said main power storage device by said external power source;

a power control unit for controlling driving of an electric motor for generating vehicle driving power, by electric power conversion between said main power storage device and said electric motor;

a first switch connected between said main power storage device and said power control unit;

a second switch connected parallel to said first switch, between said charger and said main power storage device;

a plurality of auxiliary loads formed to operate by the supply of electric power for auxiliary system from a power supply line connected to said sub power storage unit;

a first voltage converter for converting an output voltage of said main power storage unit to a level of an output voltage of said sub power storage device and outputting to said power supply line;

a second voltage converter, having an output capacity smaller than said first voltage converter, for converting an output voltage of said charger to the level of the output voltage of said sub power storage device and outputting to said power supply line; and

a controller operated by electric power supplied from said sub power storage device, for controlling open/close of said first and second switches as well as operation and stop of said first and second voltage converters;

wherein

said controller is adapted such that

at the start of said external charging, said first switch is opened and said second switch is closed, said first voltage converter is stopped and said second voltage converter is operated, and when the electric power for said auxiliary system is determined to be insufficient during execution of said external charging, said first voltage converter is operated.

2. The power source system for an electric powered vehicle according to claim 1, wherein

if it is determined that insufficiency of the electric power for said auxiliary system is solved while said first voltage converter is operating during execution of said external charging, said controller again stops operation of said first voltage converter, so that the electric power for said auxiliary system is supplied by the output of said second voltage converter.

3. The power source system for an electric powered vehicle according to claim 1, wherein

said first switch is connected between a main power supply line connected to said power control unit and said main power storage device;

said first voltage converter is electrically connected between said main power supply line and said power supply line; and

said controller is adapted such that when said first voltage converter is operated during execution of said external charging, said first switch is also closed.

4. The power source system for an electric powered vehicle according to claim 3, wherein

said controller is adapted such that

if an output of said sub power storage device becomes lower than a prescribed lower limit level while said electric powered vehicle is not running, said first switch is closed and said first voltage converter is operated, so that said sub power storage device is charged by the electric power from said main power storage device.

5. The power source system for an electric powered vehicle according to claim 1, wherein

said plurality of auxiliary loads include

a first auxiliary load electrically connected through a third switch to said power supply line, and

a second auxiliary load electrically connected to said power supply line not through said third switch;

and

said controller opens said third switch at the time of said external charging.

6. The power source system for an electric powered vehicle according to claim 1, wherein

when a voltage of said power supply line becomes lower than a prescribed voltage during execution of said external charging, said controller determines that the electric power for said auxiliary system is insufficient.

7. The power source system for an electric powered vehicle according to claim 6, wherein

said prescribed voltage is determined corresponding to a lower limit voltage ensuring operations of said plurality of auxiliary loads and said controller.

8. A method of controlling a power source system for an electric powered vehicle chargeable by an external power source outside of the vehicle;

wherein

said power source system including

rechargeable main power storage device and sub power storage device,

a charger for converting electric power supplied from said external power source to an electric power for charging said main power storage device, at a time of external charging for charging said main power storage device by said external power source,

a power control unit for controlling driving of an electric motor for generating vehicle driving power, by electric power conversion between said main power storage device and said electric motor,

a first switch connected between said main power storage device and said power control unit,

a second switch connected parallel to said first switch, between said charger and said main power storage device,

a plurality of auxiliary loads formed to operate by the supply of electric power for auxiliary system from a power supply line connected to said sub power storage unit,

a first voltage converter for converting an output voltage of said main power storage unit to a level of an output voltage of said sub power storage device and outputting to said power supply line, and

a second voltage converter, having an output capacity smaller than said first voltage converter, for converting an output voltage of said charger to the level of the output voltage of said sub power storage device and outputting to said power supply line;

said control method comprising the steps of;

confirming that said first switch is opened at the start of said external charging;

when opening of said first switch is confirmed, closing said second switch, and activating said second voltage converter;

after closing said second switch, externally charging said main power storage device by an output of said charger; and

if the electric power for said auxiliary system is determined to be insufficient during said external charging, operating said first voltage converter.

9. The method of controlling power source system for an electric powered vehicle according to claim 8, further comprising the step of

again stopping operation of said first voltage converter, if it is determined that insufficiency of the electric power for said auxiliary system is solved while said first voltage converter is operating during execution of said external charging.

10. The method of controlling power source system for an electric powered vehicle according to claim 8, wherein

said first switch is connected between a main power supply line connected to said power control unit and said main power storage device;

said first voltage converter is electrically connected between said main power supply line and said power supply line;

said control method further comprising,

the step of closing said first switch and operating said first voltage converter, so that said sub power storage device is charged by the electric power from said main power storage device, if an output of said sub power storage device becomes lower than a prescribed lower limit level while said electric powered vehicle is not running.

11. The method of controlling power source system for an electric powered vehicle according to claim 8, wherein

at said operating step, when a voltage of said power supply line becomes lower than a prescribed voltage during execution of said external charging, the electric power for said auxiliary system is determined to be insufficient.

12. The method of controlling power source system for an electric powered vehicle according to claim 11, wherein

said prescribed voltage is determined corresponding to a lower limit voltage ensuring operations of said plurality of auxiliary loads and said controller.