AC current control of mobile battery chargers

• US 8,638,063 B2
• Filed: 10/13/2010
• Issued: 01/28/2014
• Est. Priority Date: 10/13/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Paryani, Anil, Nergaard, Troy A., Baglino, Andrew
• Primary Examiner(s): Berhanu, Samuel
• Application Number:
  US12/903,388
• Publication Number:
  US 20120091953A1
• Time in Patent Office: 1,203 Days
• Field of Search: 320/104, 320/109, 320/115
• US Class Current: 320/109
• CPC Class Codes: B60L 53/63 in response to network capacity
• 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: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H02J 7/007 Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• 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]

Abstract

A charging system and method that improves utilization of available AC power during onboard charging of energy storage systems of electric vehicles. An onboard charging method for an energy storage system of an electric vehicle, the method using an AC power source, includes a) establishing a maximum DC charging current for the energy storage system responsive to a control signal indicating real-time available current/power from the AC source; and b) controlling a charging system to provide an actual DC charging current, up to the maximum DC charging current, to the energy storage system.

Claims

1. An onboard charging method for an energy storage system of an electric vehicle, the method using an AC power source, the method comprising the steps of:

a) evaluating a first process control loop to set a reference DC current responsive to a difference between a DC target voltage for the energy storage system and a voltage feedback for the energy storage system, said first process control loop setting said reference DC current at a value ranging between a target discharging current and a target charging current for the energy storage system; and

b) evaluating a second process control loop to set a control signal responsive to a difference between said reference DC current and a generated DC current provided to the energy storage system for charging, said second process control loop setting said control signal at a value ranging between a maximum DC discharging current and a maximum DC charging current derived from an available real-time AC current; and

c) controlling a charger onboard the electric vehicle responsive to said control signal to produce said generated DC current.

2. The method of claim 1, wherein the energy storage system comprises Lithium metal oxide technology.

3. The method of claim 1, wherein at least one of the first and second process control loops comprises a proportional-integral controller.

4. The method of claim 1, further comprising setting the maximum DC discharging current to zero Amperes.

5. The method of claim 1, further comprising setting the maximum DC discharging current to an actual discharge current.

6. The method of claim 1, wherein evaluating the first and second process control loops comprises a first operational mode for charging the energy storage system, the method further comprising operating the energy storage system in a second operational mode.

7. The method of claim 6, wherein the second operational mode comprises discharging the energy storage system into an electrical grid.

8. The method of claim 7, further comprising, after operating the energy storage system in the second operational mode, setting discharge parameters to zero.

9. The method of claim 1, further comprising determining the available real-time AC current from a pilot signal of an AC power source.

10. An onboard charging method for an energy storage system of an electric vehicle, the method using an AC power source, the method comprising the steps of:

a) evaluating a first process control loop to set a reference DC current responsive to a difference between a DC target voltage for the energy storage system and a maximum DC voltage for the energy storage system, said first process control loop setting said reference DC current at a value ranging between a target discharging current and a target charging current for the energy storage system; and

b) evaluating a second process control loop to set a control signal responsive to a difference between said reference DC current and a generated DC current provided to the energy storage system for charging, said second process control loop setting said control signal at a value ranging between a maximum DC discharging current and a maximum DC charging current derived from an available real-time AC power; and

c) controlling a charger onboard the electric vehicle responsive to said control signal to produce said generated DC current.

11. The method of claim 10, wherein at least one of the first and second process control loops comprises a proportional-integral controller.

12. The method of claim 10, wherein evaluating the first and second process control loops comprises a first operational mode for charging the energy storage system, the method further comprising operating the energy storage system in a second operational mode.

13. The method of claim 12, wherein the second operational mode comprises discharging the energy storage system into an electrical grid.

14. The method of claim 13, further comprising, after operating the energy storage system in the second operational mode, setting discharge parameters to zero.

15. The method of claim 10, further comprising determining the available real-time AC current from a pilot signal of an AC power source.

16. An electronic system for charging an energy storage system of an electric vehicle, comprising:

a first process control loop setting a reference DC current responsive to a difference between a DC target voltage for the energy storage system and a voltage feedback for the energy storage system, said first process control loop setting said reference DC current at a value ranging between a target discharging current and a target charging current for the energy storage system;

a second process control loop setting a control signal responsive to a difference between said reference DC current and a generated DC current provided to the energy storage system for charging, said second process control loop setting said control signal at a value ranging between a maximum DC discharging current and a maximum DC charging current derived from an available real-time AC current; and

a charger onboard the electric vehicle producing said generated DC current responsive to said control signal.

17. The electronic system of claim 16, wherein at least one of the first and second process control loops comprises a proportional-integral controller.

18. The electronic system of claim 16, wherein the first and second process control loops comprise a first operational mode for charging the energy storage system, the electronic system further comprising a second operational mode of discharging the energy storage system into an electrical grid.

19. An electronic system for charging an energy storage system of an electric vehicle, comprising:

a first process control loop setting a reference DC current responsive to a difference between a DC target voltage for the energy storage system and a maximum DC voltage for the energy storage system, said first process control loop setting said reference DC current at a value ranging between a target discharging current and a target charging current for the energy storage system;

a second process control loop setting a control signal responsive to a difference between said reference DC current and a generated DC current provided to the energy storage system for charging, said second process control loop setting said control signal at a value ranging between a maximum DC discharging current and a maximum DC charging current derived from an available real-time AC current; and

a charger onboard the electric vehicle producing said generated DC current responsive to said control signal.

20. The electronic system of claim 19, wherein at least one of the first and second process control loops comprises a proportional-integral controller.