Battery charging system and method

• US 7,256,516 B2
• Filed: 07/10/2003
• Issued: 08/14/2007
• Est. Priority Date: 06/14/2000
• Status: Expired due to Term

• Current Assignee: Webasto Charging Systems, Inc. (Webasto Beteiligungs Verwaltung Gbr)
• Original Assignee: Aerovironment
• Inventors: Rippel, Wally E., Buchanan, William D., Mohos, Joseph F.
• Primary Examiner(s): Sherry; Michael
• Assistant Examiner(s): DESCHERE, ANDREW M
• Application Number:
  US10/616,542
• Publication Number:
  US 20040130292A1
• Time in Patent Office: 1,496 Days
• Field of Search: 320/109, 320/126, 320/124, 307/43, 307/80, 307/35, 307/62, 307/82, 700/297
• US Class Current: 307/62
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/53 Batteries
• CPC Class Codes: B60L 53/63 in response to network capacity
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 53/67 Controlling two or more charging stations
• CPC Class Codes: B60L 55/00 Arrangements for supplying energy stored within a vehicle to a power network, i.e. vehicle-to-grid [V2G] arrangements
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: B60R 16/03 for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H02J 1/14 Balancing the load in a network
• CPC Class Codes: H02J 2310/46 for ICE-powered road vehicles
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• 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 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 10/126 : the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

A charging system for simultaneously charging the batteries of a plurality of battery powered vehicles. The charging includes one or more DC-DC power converters having one or more charging ports configured to plug into the batteries. The DC-DC power converters are each configured to selectively connect to more than one charging port to selectively provide for higher port power levels. The DC-DC power converters connect to an AC rectifier through a DC bus. The AC rectifier connects to an AC power source having a limited power rating. The AC charging system also has a controller that controls the operation of the DC-DC power converters such that the total power draw on the AC rectifier does not exceed the power rating. The system is further configured such that the DC-DC power converters can drain selected batteries to obtain power for charging other batteries, thus allowing for batteries to be cycled.

Claims

1. A charging system for charging a plurality of batteries from a power source, comprising:

a primary power port configured to receive power from the power source, the primary power port being characterized by a power rating;

a plurality of secondary power ports configured to distribute power from the primary power port to the plurality of batteries, each secondary power port being characterized by a power rating, wherein the sum of the secondary power port power ratings exceeds the primary power port power rating;

one or more power converters configured to receive power from the primary power port and to provide power to the plurality of secondary power ports, the one or more power converters having a capacity to receive power from the primary power port at a level above the primary power port power rating, and

a system controller including a power controller configured to regulate the power received from the primary power port by the one or more power converters to below the primary port power rating.

2. The system of claim 1, with at least some of the plurality of batteries having battery controllers separate from the system controller, wherein the system controller is configured to regulate power received from the primary power port by transmitting command signals appropriate to direct the battery controllers to regulate the power drawn by their respective batteries.

3. The system of claim 1, wherein the system controller is configured to operate at least one secondary power port of the plurality of secondary power ports bidirectionally.

4. The system of claim 1, wherein the system controller is configured to operate the primary power port bidirectionally.

5. The system of claim 1, and further comprising a buffer battery, wherein the system controller is further configured to distribute power from the buffer battery to at least one secondary power port of the plurality of secondary power ports.

6. The system of claim 5, wherein:

the system controller is configured to direct power from the primary power port to the buffer battery when the power provided by the primary power port does not exceed the primary power port power rating; and

the system controller is configured to direct power from the buffer battery to the at least one secondary power port when the plurality of batteries merits a net distribution of power from the secondary power ports in excess of the primary power port power rating.

7. An electric vehicle system for use with power from a power source, comprising:

a plurality of electric vehicles, each electric vehicle having an associated battery; and

the charging system of claim 1.

8. The system of claim 7, and further comprising a buffer battery, wherein the system controller is further configured to distribute power from the buffer battery to at least one secondary power port of the plurality of secondary power ports.

9. The system of claim 8, wherein:

the system controller is configured to direct power from the primary power port to the buffer battery when the power provided by the primary power port does not exceed the primary power port power rating; and

the system controller is configured to direct power from the buffer battery to the at least one secondary power port when the plurality of batteries merits a net distribution of power from the secondary power ports in excess of the primary power port power rating.

10. The system of claim 1, and further comprising:

a first charging module, wherein the plurality of secondary power ports includes a first secondary power port and a second secondary power port that receive power from the primary power port via the first charging module, the first charging module including

a first power converter of the one or more power converters, the first power converter connecting to the first secondary power port,

a second power converter of the one or more power converters, the second power converter connecting to the second secondary power port,

a crossover switch switchably connecting the first power converter to the second secondary power port, and

a module controller configured to control the operation of the crossover switch and establish the power distribution between the first and second secondary power ports.

11. The charging system of claim 10, wherein:

the first power converter of the first charging module connects to the first secondary power port through a first connecting switch of the first charging module;

the second power converter of the first charging module connects to the second secondary power port through a second connecting switch of the first charging module; and

the module controller of the first charging module is configured to control the operation of the first and second connecting switches and establish the power distribution between the first and second secondary power ports.

12. The charging system of claim 11, wherein the module controller for the first charging module is separate from the power controller, and wherein the power controller and the module controller for the first charging module communicate to determine the operation of the crossover switch and the first and second connecting switches.

13. A charging system for charging a plurality of batteries from one or more power sources, comprising:

a plurality of primary power ports configured to concurrently receive power from the one or more power sources, wherein each primary power port is characterized by a power rating;

a plurality of secondary power ports configured to distribute power from the plurality of primary power ports to the plurality of batteries, each secondary power port being characterized by a power rating, wherein the sum of the secondary power port power ratings exceeds the sum of the primary power port power ratings;

one or more power converters configured to receive power from the plurality of primary power ports and to provide power to the plurality of secondary power ports, the one or more power converters having a capacity to receive power from the plurality of primary power ports at a level above the sum of the primary power port power ratings, and

a system controller including a power controller configured to regulate the power received from the plurality of primary power ports by the one or more power converters to below the sum of the primary port power ratings.

14. The system of claim 13, wherein the system controller is further configured to regulate the power received from each primary power port of the plurality of primary power ports such that the power received from each primary power port does not exceed its respective power rating.

15. The system of claim 13, with at least some of the plurality of batteries having battery controllers separate from the power controller, wherein the power controller is configured to regulate the power received from the plurality of primary power ports by transmitting command signals appropriate to direct the battery controllers to regulate the power drawn by their respective batteries.

16. The system of claim 13, wherein the system controller is configured to operate at least one secondary power port of the plurality of secondary power ports bidirectionally.

17. The system of claim 13, wherein the system controller is configured to operate at least one of the plurality of primary power ports bidirectionally.

18. The system of claim 13, and further comprising a buffer battery, wherein the system controller is further configured to distribute power from the buffer battery to at least one secondary power port of the plurality of secondary power ports.

19. The system of claim 18, wherein:

the system controller is configured to direct power from the plurality of primary power ports to the buffer battery when the power provided by the primary power ports does not exceed the sum of the primary power port power ratings; and

the system controller is configured to direct power from the buffer battery to the at least one secondary power port when the plurality of batteries merits a net distribution of power from the secondary power ports in excess of the sum of the primary power port power ratings.

20. An electric vehicle system for use with power from a power source, comprising:

a plurality of electric vehicles, each electric vehicle having an associated battery; and

the charging system of claim 13.

21. The system of claim 20, and further comprising a buffer battery, wherein the system controller is further configured to distribute power from the buffer battery to at least one secondary power port of the plurality of secondary power ports.

22. The system of claim 20, wherein:

the system controller is configured to direct power from the plurality of primary power ports to the buffer battery when the power provided by the primary power ports does not exceed the sum of the primary power port power ratings; and

the system controller is configured to direct power from the buffer battery to the at least one secondary power port when the plurality of batteries merits a net distribution of power from the secondary power ports in excess of the sum of the primary power port power ratings.

23. The system of claim 13, and further comprising:

a first charging module, wherein the plurality of secondary power ports includes a first secondary power port and a second secondary power port that receive power from the plurality of primary power ports via the first charging module, the first charging module including

a first power converter of the one or more power converters, the first power converter connecting to the first secondary power port,

a second power converter of the one or more power converters, the second power converter connecting to the second secondary power port,

a crossover switch switchably connecting the first power converter to the second secondary power port, and

a module controller configured to control the operation of the crossover switch and establish the power distribution between the first and second secondary power ports.

24. The charging system of claim 23, wherein:

the first power converter of the first charging module connects to the first secondary power port through a first connecting switch of the first charging module;

the second power converter of the first charging module connects to the second secondary power port through a second connecting switch of the first charging module; and

the module controller of the first charging module is configured to control the operation of the first and second connecting switches and establish the power distribution between the first and second secondary power ports.

25. The charging system of claim 24, wherein the module controller for the first charging module is separate from the power controller, and wherein the power controller and the module controller for the first charging module communicate to determine the operation of the crossover switch and the first and second connecting switches.

26. A charging system for charging a plurality of batteries using power from a utility at a power level not exceeding a maximum power level, comprising:

a plurality of secondary power ports, each secondary power port being configured to electrically connect to at least one of the plurality of batteries, each secondary power port being characterized by a power rating;

a utility port configured to electrically connect to the utility, and to provide power from the utility to the plurality of secondary power ports;

a system controller including a power controller configured to control the power distribution between the utility port and the plurality of secondary power ports, wherein if the sum of the power ratings of the secondary power ports used to charge the plurality of batteries exceeds the maximum power level, the system controller controls the power distribution such that the plurality of batteries are simultaneously charged using power from the utility at a power level not exceeding the maximum power level; and

a first charging module, wherein the plurality of secondary power ports includes a first secondary power port and a second secondary power port that receive power from the utility port via the first charging module, the first charging module including

a first power converter connecting to the first secondary power port,

a second power converter connecting to the second secondary power port,

a crossover switch switchably connecting the first power converter to the second secondary power port, and

a module controller configured to control the operation of the crossover switch and establish the power distribution between the first and second secondary power ports;

wherein the first power converter of the first charging module connects to the first secondary power port through a first connecting switch of the first charging module;

wherein the second power converter of the first charging module connects to the second secondary power port through a second connecting switch of the first charging module;

wherein the module controller of the first charging module is configured to control the operation of the first and second connecting switches and establish the power distribution between the first and second secondary power ports;

wherein the module controller for the first charging module is separate from the power controller; and

wherein the power controller and the module controller for the first charging module communicate to determine the operation of the crossover switch and the first and second connecting switches.

27. A charging system for charging a plurality of batteries using power from a utility at a power level not exceeding a maximum power level, comprising:

a plurality of secondary power ports, each secondary power port being configured to electrically connect to at least one of the plurality of batteries, each secondary power port being characterized by a power rating;

a utility port configured to electrically connect to the utility, and to provide power from the utility to the plurality of secondary power ports;

a system controller including a power controller configured to control the power distribution from the utility port; and

a first charging module, wherein the plurality of secondary power ports includes a first secondary power port and a second secondary power port that receive power from the utility port via the first charging module, the first charging module including

a first power converter connecting to the first secondary power port,

a second power converter connecting to the second secondary power port,

a crossover switch switchably connecting the first power converter to the second secondary power port, and

a module controller configured to control the operation of the crossover switch and establish the power distribution between the first and second secondary power ports;

wherein the first power converter of the first charging module connects to the first secondary power port through a first connecting switch of the first charging module;

wherein the second power converter of the first charging module connects to the second secondary power port through a second connecting switch of the first charging module;

wherein the module controller of the first charging module is configured to control the operation of the first and second connecting switches and establish the power distribution between the first and second secondary power ports;

wherein the module controller for the first charging module is separate from the power controller; and

wherein the power controller and the module controller for the first charging module communicate to determine the operation of the crossover switch and the first and second connecting switches.

28. A charging system for charging a plurality of batteries from a power source, comprising:

a primary power port configured to receive power from the power source, the primary power port being characterized by a power rating;

a plurality of power converters configured to receive power from the primary power port, the power converters having a capacity to receive power from the primary power port at a level above the primary power port power rating;

a plurality of secondary power ports configured to distribute power from the plurality of power converters, each secondary power port being characterized by a power rating, wherein the sum of the secondary power port power ratings exceeds the primary power port power rating; and

a system controller configured to regulate the power that the plurality of converters draws such that if the sum of the power ratings of the secondary power ports simultaneously used to charge batteries exceeds the primary power port power rating, the power received from the primary power port does not exceed the primary power port power rating.

29. A charging system for charging a plurality of batteries from a plurality of power sources, comprising:

a plurality of primary power ports configured to receive power from the plurality of power sources, each primary power port being characterized by a power rating;

a plurality of power converters configured to receive power from the plurality of primary power ports, the power converters having a capacity to receive power from the plurality of primary power ports at a level above the sum of the primary power port power ratings;

a plurality of secondary power ports configured to distribute power from the plurality of power converters, each secondary power port being characterized by a power rating, wherein the sum of the secondary power port power ratings exceeds the sum of the primary power port power ratings; and

a system controller configured to regulate the power that the plurality of power converters draws such that if the sum of the power ratings of the secondary power ports simultaneously used to charge batteries exceeds the sum of the primary power port power ratings, the power received from the primary power ports does not exceed the sum of the primary power port power ratings.

30. The system of claim 29, wherein the system controller is further configured to regulate the power received from each primary power port of the plurality of primary power ports such that the power received from each primary power port does not exceed its respective power rating.