Power limiting circuit for electric vehicle battery charger

• US 5,736,831 A
• Filed: 08/22/1996
• Issued: 04/07/1998
• Est. Priority Date: 08/22/1996
• Status: Expired due to Term

• Current Assignee: Perfect Galaxy International Limited
• Original Assignee: Northrop Grumman Corporation
• Inventors: Harrington, William S.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): TOATLEY, GREGORY J
• Application Number:
  US08/701,599
• Time in Patent Office: 593 Days
• Field of Search: 363/20, 363/95, 320/9, 320/10, 320/13, 320/21, 320/22, 320/27, 320/30, 320/39, 320/49
• US Class Current: 320/104
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2240/80 Time limits
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: H02J 7/00304 Overcurrent protection
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• 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

In an electric vehicle battery charging system where the batteries of an electric vehicle are charged from an external power source including a battery energy management system which monitors the vehicle batteries and develops a current control command representing the current to be supplied to the vehicle batteries and a controllable charger having a design power limit supplies current under command of the current command at a voltage of the vehicle batteries, a charger power limiting circuit is provided and includes a voltage sensor, and a circuit for modifying the current control command to limit power to be low at least in approximation of the designed power limit of the charger. The current control command modifying circuit modifies the current control command from the BEMS to ensure that the controllable charger will not supply power to the batteries in excess of the controllable chargers design power. The charger power limiting circuit includes a power limiting characteristic defining circuit, a current limiting feedback circuit and a power limiting characteristic defining circuit. The voltage of the vehicle batteries is sensed and the current control command from the battery energy management system is used as the charging current. The current control command is then modified to limit power to below at least an approximation of the design power limit of the charger.

Claims

1. An electric vehicle battery charging system where the batteries of an electric vehicle are charged from an external power source comprising:

a battery energy management system (BEMS) monitoring the vehicle batteries and developing a current control command representing the charging current to be supplied to the vehicle batteries;

a controllable charger having a design power limit, said controllable charger being responsive to current control command from the BEMS, the current control command representing the charging current to be supplied by the controllable charger to the vehicle batteries; and

a charger power limiting circuit limiting power supplied by the controllable charger to below the charger design power limit including,

a voltage sensor measuring the voltage of the vehicle batteries, and

means for modifying the current control command to limit power to below at least an approximation of the design power limit of said charger based on the sensed battery voltage and the battery charging current, said means for modifying using the current control command from the BEMS to represent battery charging current without said controllable charger or charger power limiting circuit directly measuring charging current.

2. The system of claim 1 wherein said means for modifying limits the current control command according to a substantially linear current-voltage curve from the voltage developing the design power limit at a maximum charging current to the current developing the design power limit at a maximum charging voltage.

3. The system of claim 1 wherein said means for modifying includes a power limiting characteristic defining circuit, responsive to the voltage measured by said voltage sensor, and developing a power limiting signal representative of the current needed by the controllable charger to develop a power substantially near said design power limit at the battery voltage sensed by said voltage sensor.

4. The system of claim 3 wherein said means for modifying further includes a current limiting feedback circuit which monitors the current control command and reduces the value of said current control command when the current control command for a given battery voltage exceeds the current represented by the power limiting signal.

5. The system of claim 4 wherein said power limiting characteristic defining circuit includes a differential amplifier, a resistor voltage divider connected to one input of said differential amplifier, and a gain control feedback path controlled gain so that variations in the voltage of the vehicle batteries vary the output voltage of said power limiting amplifier 211 to produce a desired power limiting signal.

6. The system of claim 4 wherein said means for modifying further includes,

a variable gain amplifier generating said current control command,

a selective clamping differential amplifier having said power limiting signal and said current command signal connected to the differential inputs thereof, and

a feedback path provided between the output of said selective clamping differential amplifier and an input of said variable gain amplifier, said feedback path having a feedback blocking diode provided therein to prevent feedback along said path when current flows along said path in a first direction,

said selective clamping differential amplifier having a blocking diode and clamping zener diode serially connected in opposition so that the output of said selective clamping differential amplifier is clamped to a first voltage polarity to reverse bias said feedback blocking diode when said current command signal has a level less than the level of said power limiting signal,

said feedback path providing a feedback signal from said selective clamping differential amplifier in proportion to the difference between said current command signal and said power limiting signal to reduce the gain of said variable gain amplifier in correspondence with this difference when said current command signal has a level greater that said power limiting signal.

7. The system of claim 6 wherein said BEMS produces a pulse width modulated current control signal, said charger power limiting circuit further including,

an analog switch for adjusting the voltage levels of the pulse width modulated signal, and

an integrator for integrating the adjusted pulse width modulated signal into a corresponding D.C. voltage current control signal.

8. A method of charging electric vehicle batteries from an external power source using a controllable charger having a design power limit, comprising:

a) monitoring the vehicle batteries and developing a current control command representing the charging current to be supplied to the vehicle batteries;

b) using the controllable charger to charge said batteries with a current defined by said current control command; and

c) limiting power supplied by the charger to below the charger design power by,

i) sensing the voltage of the vehicle batteries,

ii) using the current control command from the BEMS to represent battery charging current without said controllable charger directly measuring charging current, and

iii) modifying the current control command to limit power to below at least an approximation of the design power limit of said charger.

9. The method of claim 8 wherein said step iii) of modifying limits the current control command according to a substantially linear current-voltage curve from the voltage developing the design power limit at a maximum charging current to the current developing the design power limit at a maximum charging voltage.

10. The method of claim 9 wherein said step iii) of modifying includes,

developing a power limiting signal representative of the current needed by the controllable charger to develop a power substantially near said design power at the battery voltage sensed by said step i) of sensing, and

monitoring the current control command and reducing the value of said current control command when the current control command for a given battery voltage exceeds the current represented by the power limiting signal.

11. In an electric vehicle battery charging system where the batteries of an electric vehicle are charged from an external power source by a controllable charger having a design power limit, said controllable charger being responsive to current control command from a battery energy management system (BEMS), the current control command representing the charging current to be supplied by the controllable charger to the vehicle batteries, a charger power limiter for limiting power supplied by the charger to below the charger design power comprising:

a voltage sensor measuring the voltage of the vehicle batteries; and

means for modifying the current control command to limit power to below at least an approximation of the design power limit of said charger based on the sensed battery voltage and the battery charging current, said means for modifying using the current control command from the BEMS to represent battery charging current without the controllable charger or said charger power limiter directly measuring charging current.

12. The charger power limiter of claim 11 wherein said means for modifying limits the current control command according to a substantially linear current-voltage curve from the voltage developing the design power limit at a maximum charging current to the current developing the design power limit at a maximum charging voltage.

13. The charger power limiter of claim 11 wherein said means for modifying includes a power limiting characteristic defining amplifier, responsive to the voltage measured by said voltage sensor, and developing a power limiting signal representative of the current needed by the controllable charger to develop a power substantially near said design power limit at the battery voltage sensed by said voltage sensor.

14. The charger power limiter of claim 13 wherein said means for modifying further includes a current limiting feedback circuit which monitors the current control command and reduces the value of said current control command when the current control command for a given battery voltage exceeds the current represented by the power limiting signal.

15. The charger power limiter of claim 14 wherein said power limiting amplifier includes a differential amplifier, a resistor voltage divider connected to one input of said differential amplifier and a gain control feedback path providing a controlled gain so that variations in the voltage of the vehicle batteries varies the output voltage of said power limiting amplifier to produce a desired power limiting signal.

16. The charger power limiter of claim 14 wherein said means for modifying further includes,

a variable gain amplifier generating said current control command,

a selective clamping differential amplifier having said power limiting signal and said current command signal connected to the differential inputs thereof, and

a feedback path provided between the output of said selective clamping differential amplifier and an input of said variable gain amplifier, said feedback path having a feedback blocking diode provided therein to prevent feedback along said path when current flows along said path in a first direction,

said selective clamping differential amplifier having a blocking diode and clamping zener diode serially connected in opposition so that the output of said selective clamping differential amplifier is clamped to a first voltage polarity to reverse bias said feedback blocking diode when said current command signal has a level less than the level of said power limiting signal,

said feedback path providing a feedback signal from said selective clamping differential amplifier in proportion to the difference between said current command signal and said power limiting signal to reduce the gain of said variable gain amplifier in correspondence with this difference when said current command signal has a level greater that said power limiting signal.

17. The charger power limiter of claim 16 wherein said BEMS produces a pulse width modulated current control signal, said charger power limiting circuit further including,

an analog switch for adjusting the voltage levels of the pulse width modulated signal, and

an integrator for integrating the adjusted pulse width modulated signal into a corresponding D.C. voltage current control signal.

18. In an electric vehicle battery charging system where the batteries of an electric vehicle are charged from an external power source by a controllable charger having a design power limit, said controllable charger being responsive to current control command from a battery energy management system (BEMS), the current control command representing the charging current to be supplied by the controllable charger to the vehicle batteries, a charger power limiting method for limiting power supplied by the charger to below the charger design power comprising:

a) sensing the voltage of the vehicle batteries;

b) using the current control command from the BEMS to represent battery charging current without said charger directly measuring charging current; and

c) modifying the current control command to limit power to below at least an approximation of the design power limit of said charger based on the sensed battery voltage and the battery charging current.

19. The method of claim 18 wherein said step c) of modifying limits the current control command according to a substantially linear current-voltage curve from the voltage developing the design power limit at a maximum charging current to the current developing the design power limit at a maximum charging voltage.

20. The method of claim 19 wherein said step c) of modifying includes,

developing a power limiting signal representative of the current needed by the controllable charger to develop a power substantially near said design power limit at the battery voltage sensed by said step a) of sensing, and

monitoring the current control command and reducing the value of said current control command when the current control command for a given battery voltage exceeds the current represented by the power limiting signal.