BATTERY INTEGRATED ISOLATED POWER CONVERTER AND SYSTEMS FOR ELECTRIC VEHICLE PROPULSION

• US 20170190434A1
• Filed: 12/30/2015
• Published: 07/06/2017
• Est. Priority Date: 12/30/2015
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Dong, Dong, Shah, Manoj Ramprasad, Zhou, Rui, Zhang, Di, Huang, Hao
• Granted Patent: US 10,351,253 B2
• Time in Patent Office: Days
• CPC Class Codes: B60Y 2200/51 Aeroplanes
• CPC Class Codes: B60Y 2200/92 Hybrid vehicles
• CPC Class Codes: B64D 2221/00 Electric power distribution systems onboard aircraft
• CPC Class Codes: B64D 27/026 comprising different types of power plants, e.g. combination of a piston engine and a gas-turbine Hybrid electric aircraft B64D27/33
• CPC Class Codes: B64D 27/24 using steam or spring force jet aircraft B64D27/16
• CPC Class Codes: H02M 1/0077 Plural converter units whose outputs are connected in series
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/483 Converters with outputs that each can have more than two voltages levels
• CPC Class Codes: H02M 7/4835 comprising two or more cells, each including a switchable capacitor, the capacitors having a nominal charge voltage which corresponds to a given fraction of the input voltage, and the capacitors being selectively connected in series to determine the instantaneous output voltage
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters
• CPC Class Codes: H02M 7/797 using semiconductor devices only
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor

Abstract

An electric propulsion system includes at least one generator. The electric propulsion system also includes at least one drive engine coupled to the at least one generator. The electric propulsion system further includes at least one electrical device. The electric propulsion system also includes at least one battery integrated isolated power converter (BIIC), where the at least one generator and at least one of the at least one BIIC and the at least one electrical device are coupled, and where the at least one BIIC and the at least one electrical device are coupled.

Claims

1. An electric propulsion system for a vehicle, said electric propulsion system comprising:

at least one generator;

at least one drive engine coupled to said at least one generator;

at least one electrical device; and

at least one battery integrated isolated power converter (BIIC), wherein said at least one generator and at least one of said at least one BIIC and said at least one electrical device are coupled, and wherein said at least one BIIC and said at least one electrical device are coupled.

2. The electric propulsion system in accordance with claim 1, wherein said at least one BIIC comprises:

a DC link; and

at least a first BIIC and a second BIIC, each of said first BIIC and said second BIIC comprising;

a first DC line coupled to said DC link; and

a second DC line coupled to said DC link, said electric propulsion system further comprising;

a DC interconnect coupled to and between said first BIIC and second BIIC, said DC interconnect comprising a first DC bus coupled to and between said first DC line of said first BIIC and said first DC line of said second BIIC, said DC interconnect further comprising a second DC bus coupled to and between said second DC line of said first BIIC and said second DC line of said second BIIC.

3. The electric propulsion system in accordance with claim 1 further comprising at least one generator rectifier coupled to and between said at least one BIIC and said at least one generator, said at least one generator comprising an AC generator.

4. The electric propulsion system in accordance with claim 3, wherein:

said AC generator further comprises at least a first AC generator and a second AC generator;

said at least one generator rectifier comprises at least a first generator rectifier and a second generator rectifier; and

said electric propulsion system further comprises at least one rectifier bus coupled to and between said first generator rectifier and said second generator rectifier.

5. The electric propulsion system in accordance with claim 1, wherein:

the vehicle is an aircraft;

said electric propulsion system further comprises at least one fan coupled to an aft portion of a fuselage of the aircraft proximate a tail of the aircraft;

said at least one electrical device comprises at least one motor coupled to the aft portion of the fuselage; and

said at least one motor configured to rotate said at least one fan in at least one of a clockwise and a counterclockwise direction to facilitate propulsion of the aircraft.

6. The electric propulsion system in accordance with claim 1, wherein:

the vehicle is an aircraft; and

said at least one BIIC coupled to at least one of the following;

a fuselage of the aircraft proximate a wing of the aircraft; and

an aft portion of a fuselage of the aircraft.

7. The electric propulsion system in accordance with claim 1, wherein:

the vehicle is an aircraft; and

said at least one BIIC comprises at least one fore BIIC and at least one aft BIIC coupled together, wherein;

said at least one fore BIIC coupled to a fuselage of the aircraft proximate a wing of the aircraft; and

said at least one aft BIIC coupled to an aft portion of the fuselage.

8. The electric propulsion system in accordance with claim 3, wherein:

said AC generator comprises at least a first AC generator and a second AC generator;

said at least one generator rectifier comprises at least a first generator rectifier and a second generator rectifier; and

said at least one BIIC comprises;

a DC link; and

at least a first BIIC and a second BIIC, said electric propulsion system further comprising;

a first extension and a second extension;

a first generator cable coupled to and between said first generator rectifier and said first BIIC; and

a second generator cable coupled to and between said second generator rectifier and said second BIIC, each of said first BIIC and said second BIIC comprising a first DC line and a second DC line, both coupled to said DC link, wherein;

said first extension coupled to and between said first generator cable and said first DC line of said second BIIC; and

said second extension coupled to and between said second generator cable and said second DC line of said first BIIC.

9. The electric propulsion system in accordance with claim 1 further comprising at least one AC/AC power converter coupled to and between said at least one generator and said at least one BIIC, wherein:

said electric propulsion system further comprising at least one AC line coupled to and between said at least one AC/AC power converter and said at least one electrical device; and

said at least one BIIC coupled to said at least one AC line.

10. The electric propulsion system in accordance with claim 9, wherein:

the vehicle is an aircraft; and

said at least one AC/AC power converter comprises;

at least one fore AC/AC power converter and at least one aft AC/AC power converter coupled together, wherein;

said at least one fore AC/AC power converter coupled to a fuselage of the aircraft proximate a wing of the aircraft; and

said at least one aft AC/AC power converter coupled to an aft portion of the fuselage.

11. A battery integrated isolated power converter (BIIC) comprising:

at least one BIIC module (BIICM) string comprising a plurality of BIICMs coupled to each other, each BIICM of said plurality of BIICMs comprising;

a first BIICM circuit comprising a first plurality of switching devices coupled together;

a second BIICM circuit comprising a second plurality of switching devices coupled together; and

a BIICM high-frequency transformer coupled to and between said first BIICM circuit and said second BIICM circuit, wherein said first BIICM circuit and said second BIICM circuit are physically isolated and inductively coupled through said BIICM high-frequency transformer.

12. The BIIC in accordance with claim 11, wherein:

said first BIICM circuit further comprises;

a first switching device and a second switching device coupled to said first switching device; and

a third switching device and a fourth switching device coupled to said third switching device, both of said first switching device and said second switching device coupled in parallel across both of said third switching device and said fourth switching device;

said second BIICM circuit further comprises;

a fifth switching device and a sixth switching device coupled to said fifth switching device;

said BIICM high-frequency transformer comprises;

a first winding coupled in parallel across at least one of said third switching device and said fourth switching device; and

a second winding coupled in parallel across at least one of said fifth switching device and said sixth switching device, each BIICM of said plurality of BIICMs further comprising;

at least one of at least one energy storage device and at least one capacitor coupled in parallel across at least one of;

both of said first switching device and said second switching device; and

both of said fifth switching device and said sixth switching device.

13. The BIIC in accordance with claim 12, wherein:

said at least one BIICM string further comprises at least three shunt strings, each shunt string of said at least three shunt strings comprising at least a topmost BIICM and a bottommost BIICM;

said first BIICM circuit further comprises;

a first node defined between said first switching device and said second switching device;

a second node defined between said first switching device and said third switching device; and

a third node defined between said second switching device and said fourth switching device; and

said BIIC further comprises;

at least three alternating current (AC) lines, each AC line of said at least three AC lines configured to transmit a phase of a 3-phase AC power to and from said BIIC, wherein;

said first node of said topmost BIICM of each shunt string of said at least three shunt strings coupled to one AC line of said at least three AC lines;

each said third node of each said bottommost BIICM of each shunt string of said at least three shunt strings coupled together; and

said first nodes and said third nodes of all said BIICMs other than said topmost BIICM and said bottommost BIICM of said each shunt string of said at least three shunt strings serially coupled.

14. The BIIC in accordance with claim 12 further comprising:

a bypass switch coupled in parallel across at least one of said first switching device and said second switching device; and

a bypass switch controller coupled to said bypass switch, said bypass switch controller configured to transmit a control signal to said bypass switch to open said bypass switch when at least one characteristic associated with said BIICM has a first predetermined value and close said bypass switch when the at least one characteristic has a second predetermined value different from the first predetermined value.

15. The BIIC in accordance with claim 12, wherein said first BIICM circuit further comprises:

a first node defined between said first switching device and said second switching device;

a second node defined between said first switching device and said third switching device;

a third node defined between said second switching device and said fourth switching device;

a direct current (DC) link; and

a first AC line configured to transmit a phase of a 3-phase AC power to and from said BIIC, wherein said at least one BIICM string further comprises;

a first half string comprising a first plurality of BIICMs comprising at least a first topmost BIICM and a first bottommost BIICM;

a second half string comprising a second plurality of BIICMs comprising at least a second topmost BIICM and a second bottommost BIICM; and

a power terminal coupled to and between said first half string and said second half string, said power terminal further coupled to said first AC line.

16. The BIIC in accordance with claim 15 further comprising a first inductor and a second inductor, wherein:

said first inductor coupled to and between said power terminal and said third node of said first bottommost BIICM; and

said second inductor coupled to and between said power terminal and said first node of said second topmost BIICM.

17. The BIIC in accordance with claim 12, wherein said second BIICM circuit further comprises a seventh switching device and an eighth switching device coupled to said seventh switching device, both of said seventh switching device and said eighth switching device coupled in parallel across both of said fifth switching device and said sixth switching device.

18. The BIIC in accordance with claim 17 further comprising:

a bypass switch coupled in parallel across at least one of said seventh switching device and said eighth switching device; and

a bypass switch controller coupled to said bypass switch, said bypass switch controller configured to transmit a control signal to said bypass switch to open said bypass switch when at least one characteristic associated with said BIICM has a first predetermined value and close said bypass switch when the at least one characteristic has a second predetermined value different from the first predetermined value.

19. The BIIC in accordance with claim 17, wherein:

said first BIICM circuit further comprises;

a first node defined between said first switching device and said second switching device;

a second node defined between said first switching device and said third switching device; and

a third node defined between said second switching device and said fourth switching device;

said second BIICM circuit further comprises;

a fourth node defined between said sixth switching device and said eighth switching device; and

a fifth node defined between said seventh switching device and said eighth switching device; and

said BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus; and

at least three first AC lines, wherein;

said at least one BIICM string further comprises at least three BIICM sets, said at least three BIICM sets comprising a topmost BIICM set and a bottommost BIICM set, each BIICM set of said at least three BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

said first node of each BIICM of each BIICM set of said at least three BIICM sets coupled together and further coupled to one first AC line of said at least three first AC lines, each first AC line of said at least three first AC lines configured to transmit a phase of a 3-phase AC power to and from said BIIC;

both of said fifth node of said topmost BIICM of said topmost BIICM set and said fourth node of said bottommost BIICM of said bottommost BIICM set coupled to said DC link;

said second nodes of all said BIICMs of said BIIC coupled together through said first nodal bus;

said third nodes of all said BIICMs of said BIIC coupled together through said second nodal bus; and

said fourth nodes and said fifth nodes of all said BIICMs other than said topmost BIICM of said topmost BIICM set and said bottommost BIICM of said bottommost BIICM set serially coupled.

20. The BIIC in accordance with claim 17, wherein:

said first BIICM circuit further comprises;

a first node defined between said first switching device and said second switching device;

a second node defined between said first switching device and said third switching device; and

a third node defined between said second switching device and said fourth switching device;

said second BIICM circuit further comprises;

a fourth node defined between said sixth switching device and said eighth switching device; and

a fifth node defined between said seventh switching device and said eighth switching device;

said BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus; and

at least three first AC lines; and

said at least one BIICM string further comprises at least three BIICM sets, said at least three BIICM sets comprising a topmost BIICM set and a bottommost BIICM set, each BIICM set of said at least three BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

said first node of each BIICM of each BIICM set of said at least three BIICM sets coupled together and further coupled to one first AC line of said at least three first AC lines, each first AC line of said at least three first AC lines configured to transmit a phase of a 3-phase AC power to and from said BIIC;

each of said fifth node of said topmost BIICM and said fourth node of said bottommost BIICM of each BIICM set of said at least three BIICM sets coupled to said DC link;

said second nodes of all BIICMs of said BIIC coupled together through said first nodal bus;

said third nodes of all BIICMs of said BIIC coupled together through said second nodal bus; and

said fourth nodes and said fifth nodes of all BIICMs other than said topmost BIICM and said bottommost BIICM of each BIICM set of said at least three BIICM sets serially coupled together.

21. The BIIC in accordance with claim 15 further comprising at least three of said first AC line and at least three panels, each panel of said at least three panels comprising one of said at least one BIICM string, wherein:

both of said third node of said first bottommost BIICM and said first node of said second topmost BIICM coupled to said power terminal;

both of said first node of said first topmost BIICM and said third node of said second bottommost BIICM coupled to said DC link;

said first nodes of all said BIICMs of said first half string other than said first node of said first topmost BIICM serially coupled to said third nodes of said all BIICMs of said first half string other than said third node of said first bottommost BIICM; and

said first nodes of all said BIICMs of said second half string other than said first node of said second topmost BIICM serially coupled to said third nodes of said all BIICMs of said second half string other than said third node of said second bottommost BIICM.

22. The BIIC in accordance with claim 11, wherein said BIICM high-frequency transformer comprises a plurality of first windings and at least one second winding, wherein a number of said plurality of first windings is greater than a number of said at least one second winding.

23. The BIIC in accordance with claim 17, wherein said second BIICM circuit further comprises a ninth switching device and a tenth switching device coupled to said tenth switching device, both of said ninth switching device and said tenth switching device coupled in parallel across both of said seventh switching device and said eighth switching device.

24. The BIIC in accordance with claim 23, wherein:

said first BIICM circuit further comprises;

a first node defined between said first switching device and said second switching device;

a second node defined between said first switching device and said third switching device; and

a third node defined between said second switching device and said fourth switching device;

said second BIICM circuit further comprises;

a fifth node defined between said seventh switching device and said eighth switching device; and

a sixth node defined between said ninth switching device and said tenth switching device;

said BIIC further comprises;

a DC link;

a first nodal bus;

a second nodal bus;

at least three first AC lines;

at least three second AC lines; and

said at least one BIICM string further comprises at least three BIICM sets, said at least three BIICM sets comprising a topmost BIICM set and a bottommost BIICM set, each BIICM set of said at least three BIICM sets comprising at least a topmost BIICM and a bottommost BIICM, wherein;

said first node of each said at least a topmost BIICM and said bottommost BIICM of each BIICM set of said at least three BIICM sets coupled together and further coupled to one first AC line of said at least three AC lines, each first AC line of said at least three first AC lines configured to transmit a phase of a 3-phase AC power to and from said BIIC;

said fifth node of said topmost BIICM of said each BIICM set of said at least three BIICM sets coupled to one second AC line of said at least three second AC lines, each second AC line of said at least three second AC lines configured to transmit a phase of a 3-phase AC power to and from said BIIC;

said second nodes of all said BIICMs of said BIIC coupled together through said first nodal bus;

said third nodes of all said BIICMs of said BIIC coupled together through said second nodal bus;

said fifth nodes and said sixth nodes and said fifth nodes of all said BIICMs other than said topmost BIICM and said bottommost BIICM of said each BIICM set of said at least three BIICM sets serially coupled; and

said sixth nodes of all said bottommost BIICMs of each said BIICM set of said at least three BIICM sets coupled together.