Protecting switch contacts of relay apparatus from electrical arcing in electric vehicle

• US 9,302,593 B2
• Filed: 11/21/2013
• Issued: 04/05/2016
• Est. Priority Date: 08/02/2013
• Status: Active Grant

• Current Assignee: Delta Electronics Incorporated
• Original Assignee: Delta Electronics Incorporated
• Inventors: Wu, Tsung-Yuan, Liu, Xin-Wei
• Primary Examiner(s): Levin, Naum B
• Application Number:
  US14/086,172
• Publication Number:
  US 20150035485A1
• Time in Patent Office: 866 Days
• US Class Current: 1/1
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• 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
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of 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 30/14 Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

An electric vehicle supply equipment receives an external AC power source. The electric vehicle supply equipment includes a relay apparatus and a controller. The relay apparatus has a master relay, an auxiliary relay, and a controllable switch. The master relay is connected to a master power loop. The controllable switch is connected in series to the auxiliary relay to form a series path and connected to an auxiliary power loop. When the controller detects the external AC power source, the controller turns on the auxiliary relay. Afterward, when the controller detects that the external AC power source is in a zero-crossing condition, the controller drives the controllable switch to be turned on. Accordingly, the relays are controlled in coordinated timing, and further the external AC power source is detected, thus implementing the zero-voltage and zero-current turning on of the relay apparatus.

Claims

1. An electric vehicle supply equipment receiving an external AC power source, the electric vehicle supply equipment comprising:

a relay apparatus comprising;

at least one master relay connected to a master power loop;

an auxiliary relay; and

a controllable switch connected in series to the auxiliary relay to form a series branch, and connected to an auxiliary power loop, wherein the series branch is connected in parallel to the at least one master relay; and

a controller configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch,

wherein when the controller is configured to detect the external AC power source, the auxiliary control signal is configured to turn on the auxiliary relay, and then the external AC power source is configured to supply power to an electric vehicle through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch, and

wherein the at least one master relay is turned on by the at least one master control signal after the electric vehicle is supplied power by the external AC power source, and then the controllable switch is turned off by the trigger control signal, and then the auxiliary relay is turned off by the auxiliary control signal while the at least one master relay remains on.

2. The electric vehicle supply equipment in claim 1, wherein the controller triggers to turn on the controllable switch when the external AC power source is not in a zero-crossing condition so that the zero-voltage turning on of the relay apparatus is achieved and the external AC power source is provided to supply power to the electric vehicle through the auxiliary power loop;

the controller triggers to turn on the controllable switch when the external AC power source is in a zero-crossing condition so that the zero-current turning on of the relay apparatus is achieved and the external AC power source is provided to supply power to the electric vehicle through the auxiliary power loop.

3. The electric vehicle supply equipment in claim 1, wherein the electric vehicle is supplied power by the external AC power source through the auxiliary power loop, and the electric vehicle is supplied power by the external AC power source through the master power loop after the controllable switch is turned off and the auxiliary relay is turned off.

4. The electric vehicle supply equipment in claim 1, wherein when the master relay is a first master relay and the master control signal is a first master control signal, the first master relay is connected to an output terminal of the master power loop, and the series branch is connected in parallel to the first master relay.

5. The electric vehicle supply equipment in claim 1, wherein the relay apparatus further comprises:

an inductance element connected in series to the series branch formed by the controllable switch and the auxiliary relay to restrain a changing rate of the current flowing through the auxiliary power loop when the controllable switch is turned on by the trigger control signal.

6. The electric vehicle supply equipment in claim 1, wherein the controllable switch is a silicon controlled rectifier (SCR), a triode AC semiconductor switch (TRIAC), or a diode for AC switch (DIAC).

7. An electric vehicle supply equipment receiving an external AC power source, the electric vehicle supply equipment comprising:

a relay apparatus comprising;

at least one master relay connected to a master power loop;

an auxiliary relay; and

a controllable switch connected in series to the auxiliary relay to form a series branch, and connected to an auxiliary power loop, wherein the series branch is connected in parallel to the at least one master relay; and

a controller configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch,

wherein when the controller is configured to detect the external AC power source, the auxiliary control signal is configured to turn on the auxiliary relay, and then the external AC power source is configured to supply power to an electric vehicle through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch, and

wherein when the master relays are a first master relay and a second master relay and the master control signals are a first master control signal and a second master control signal, the first master relay is connected to an output terminal of the master power loop, the series branch is connected in parallel to the first master relay, and the second master relay is connected to another output terminal of the master power loop;

when the controller detects the external AC power source, the auxiliary relay is turned on by the auxiliary control signal, and then the second master relay is turned on by the second master control signal, and then the controllable switch is turned on by the trigger control signal when the controller detects that the external AC power source is in a zero-crossing condition so that the electric vehicle is supplied power by the external AC power source through the auxiliary power loop.

8. An electric vehicle supply equipment receiving an external AC power source, the electric vehicle supply equipment comprising:

a relay apparatus comprising;

at least one master relay connected to a master power loop;

an auxiliary relay; and

a controllable switch connected in series to the auxiliary relay to form a series branch, and connected to an auxiliary power loop, wherein the series branch is connected in parallel to the at least one master relay; and

a controller configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch,

wherein when the controller is configured to detect the external AC power source, the auxiliary control signal is configured to turn on the auxiliary relay, and then the external AC power source is configured to supply power to an electric vehicle through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch, and

wherein when the master relays are a first master relay and a second master relay and the master control signals are a first master control signal and a second master control signal, the first master relay is connected to an output terminal of the master power loop, the series branch is connected in parallel to the first master relay, and the second master relay is connected to another output terminal of the master power loop;

when the controller detects the external AC power source, the second master relay is turned on by the second master control signal, and then the auxiliary relay is turned on by the auxiliary control signal, and then the controllable switch is turned on by the trigger control signal when the controller detects that the external AC power source is in a zero-crossing condition so that the electric vehicle is supplied power by the external AC power source through the auxiliary power loop.

9. A method of operating an electric vehicle supply equipment, the electric vehicle supply equipment receiving an external AC power source, the method comprising:

providing a relay apparatus;

wherein the relay apparatus has at least one master relay, an auxiliary relay, and a controllable switch;

the at least one master relay is connected to a master power loop, and the auxiliary relay is connected in series to the controllable switch to form a series branch and connected to an auxiliary power loop;

providing a controller;

wherein the controller is configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch;

turning on the auxiliary relay by the auxiliary control signal when the controller is configured to detect the external AC power source; and

supplying power to an electric vehicle by the external AC power source through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch,

turning on the at least one master relay by the at least one master control signal;

turning off the controllable switch by the trigger control signal; and

turning off the auxiliary relay by the auxiliary control signal so that the electric vehicle is supplied power by the external AC power source through the master power loop.

10. The method of operating the electric vehicle supply equipment in claim 9, wherein the controller triggers to turn on the controllable switch when the external AC power source is not in a zero-crossing condition so that the zero-voltage turning on of the relay apparatus is achieved and the external AC power source is provided to supply power to the electric vehicle through the auxiliary power loop;

the controller triggers to turn on the controllable switch when the external AC power source is in a zero-crossing condition so that the zero-current turning on of the relay apparatus is achieved and the external AC power source is provided to supply power to the electric vehicle through the auxiliary power loop.

11. The method of operating the electric vehicle supply equipment in claim 9, wherein when the master relay is a first master relay and the master control signal is a first master control signal, the first master relay is connected to an output terminal of the master power loop, and the series branch is connected in parallel to the first master relay.

14. The method of operating the electric vehicle supply equipment in claim 9, wherein the relay apparatus further comprises:

an inductance element connected in series to the series branch formed by the controllable switch and the auxiliary relay to restrain a changing rate of the current flowing through the auxiliary power loop when the controllable switch is turned on by the trigger control signal.

15. The method of operating the electric vehicle supply equipment in claim 9, wherein the controllable switch is a silicon controlled rectifier (SCR), a triode AC semiconductor switch (TRIAC), or a diode for AC switch (DIAC).

12. A method of operating an electric vehicle supply equipment, the electric vehicle supply equipment receiving an external AC power source, and the method comprising following steps:

providing a relay apparatus;

wherein the relay apparatus has at least one master relay, an auxiliary relay, and a controllable switch;

the at least one master relay is connected to a master power loop, and the auxiliary relay is connected in series to the controllable switch to form a series branch and connected to an auxiliary power loop;

providing a controller;

wherein the controller is configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch;

turning on the auxiliary relay by the auxiliary control signal when the controller is configured to detect the external AC power source; and

supplying power to an electric vehicle by the external AC power source through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch,

wherein when the master relays are a first master relay and a second master relay and the master control signals are a first master control signal and a second master control signal, the first master relay is connected to an output terminal of the master power loop, the series branch is connected in parallel to the first master relay, and the second master relay is connected to another output terminal of the master power loop;

when the controller detects the external AC power source, the auxiliary relay is turned on by the auxiliary control signal, and then the second master relay is turned on by the second master control signal, and then the controllable switch is turned on by the trigger control signal when the controller detects that the external AC power source is in a zero-crossing condition so that the electric vehicle is supplied power by the external AC power source through the auxiliary power loop.

13. A method of operating an electric vehicle supply equipment, the electric vehicle supply equipment receiving an external AC power source, and the method comprising following steps:

providing a relay apparatus;

wherein the relay apparatus has at least one master relay, an auxiliary relay, and a controllable switch;

the at least one master relay is connected to a master power loop, and the auxiliary relay is connected in series to the controllable switch to form a series branch and connected to an auxiliary power loop;

providing a controller;

wherein the controller is configured to produce at least one master control signal, an auxiliary control signal, and a trigger control signal to correspondingly control the at least one master relay, the auxiliary relay, and the controllable switch;

turning on the auxiliary relay by the auxiliary control signal when the controller is configured to detect the external AC power source; and

supplying power to an electric vehicle by the external AC power source through the auxiliary power loop when the controller is configured to control the trigger control signal to turn on the controllable switch,

wherein when the master relays are a first master relay and a second master relay and the master control signals are a first master control signal and a second master control signal, the first master relay is connected to an output terminal of the master power loop, the series branch is connected in parallel to the first master relay, and the second master relay is connected to another output terminal of the master power loop;

when the controller detects the external AC power source, the second master relay is turned on by the second master control signal, and then the auxiliary relay is turned on by the auxiliary control signal, and then the controllable switch is turned on by the trigger control signal when the controller detects that the external AC power source is in a zero-crossing condition so that the electric vehicle is supplied power by the external AC power source through the auxiliary power loop.