Vehicle power sharing and grid connection system for electric motors and drives

• US 9,731,609 B2
• Filed: 04/04/2014
• Issued: 08/15/2017
• Est. Priority Date: 04/04/2014
• Status: Active Grant

• Current Assignee: Unique Electric Solutions Incorporated
• Original Assignee: DG Systems LLC
• Inventors: Ambrosio, Joseph Mario
• Primary Examiner(s): Chang, Joseph
• Application Number:
  US14/245,673
• Publication Number:
  US 20150283911A1
• Time in Patent Office: 1,229 Days
• Field of Search: 307 101
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 50/11 using DC generators and DC motors
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/345 using capacitors as storage or buffering devices
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• 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

Abstract

A power sharing system for electric motors and drives shares power between multiple power sources. Multiple motor drives share power between multiple energy sources, without the need for a DC to DC converter. A motor drive adapts the DC voltage range of the power source to either AC voltage or a different DC voltage range to operate one or more electric motors. Either a capacitor bank or a battery is directly connected to a motor drive'"'"'s DC input. Two separate DC inputs exist, each able to operate at its own voltage and both feeding the same motor through separate motor drives, to allow batteries to be operated at one voltage level while capacitors are operated at another. The motor drives inherently cause power to flow between the motor and either power source, regardless of the relative voltages of the two sources, provided that each source is at a sufficient voltage to power the motor independently.

Claims

1. A power sharing system comprising:

a battery pack for supplying electric power to an electric motor;

an ultra-capacitor bank for supplying electric power in parallel with said battery pack to said electric motor;

said controller connected to a separate input of said electric motor;

each said input at its own voltage to allow said battery pack to be operated at one voltage level while said ultra-capacitor bank is operated at another voltage level;

a controller containing basic operational parameters and providing an interface to said inputs, whereby said controller matches varying torque demands of said electric motor with available power from said battery pack and ultra-capacitor whereby said ultra-capacitor has most of the power capacity of said power sharing system for providing short bursts of power when required by said motor; and

said power sharing system operating without use of a DC to DC converter.

2. Apparatus for sharing electric power between multiple energy sources in a vehicle or machine comprising:

an AC electric motor;

a first motor drive inverter for delivering a first AC current to AC motor wires of said electric motor;

a first source of DC power for delivering a DC voltage to said first motor drive inverter;

a second motor drive inverter for delivering AC current to said AC motor wires of said electric motor;

a second source of DC electric power for delivering a DC voltage to said second motor drive inverter, and

a controller connected to both of said first and second motor drive inverters containing basic operational parameters and providing an interface to the vehicle or machine, whereby said controller distributes power between said first and second sources of DC according to varying torque demands of said electric motor, and whereby said second source of DC has most of the power capacity of said power sharing system for providing short bursts of power when required by said motor.

3. The apparatus of claim 2 wherein said second motor drive inverter delivers AC current to said AC motor wires through inductors or a low pass filter to facilitate filtering of unwanted switching transients between the two inverters.

4. The apparatus of claim 2 in which said first source of DC electric power is a battery pack.

5. The apparatus of claim 2 in which said second source of DC electric power is an ultra-capacitor bank and only said second motor drive inverter is bi-directional for providing regeneration during braking.

6. The apparatus of claim 4 in which said second source of DC electric power is an ultra-capacitor bank, whereby said ultra-capacitor bank meets temporary higher energy demands of said electric motor.

7. The apparatus of claim 6 having a device for sensing the phase of the AC power coming from one of said inverters to generate a simulated encoder signal for the second inverter.

8. The apparatus of claim 6 in which said apparatus provides drive in a vehicle whereby said second source of DC electric power is utilized for acceleration of said vehicle and regeneration of said battery pack.

9. The apparatus of claim 2 wherein said apparatus operates without the use of a DC to DC converter.

10. Apparatus in a vehicle or machine for sharing electric power between multiple energy sources comprising:

a first power system comprising a first AC electric motor, a first motor drive inverter for delivering a first AC voltage to AC motor wires of said first electric motor and a first source of DC power for delivering a first DC voltage to said first motor drive inverter;

at least one further power system comprising at least one further AC electric motor, at least one further motor drive inverter for delivering at least one further AC voltage to AC motor wires of said second electric motor and at least one further source of DC electric power for delivering at least one further DC voltage to said second motor drive inverter, and wherein said apparatus operates without the use of a DC to DC converter;

said first and second AC electric motors being mechanically coupled together to operate on a common load;

said first and second power systems operating at different DC voltage levels; and

a controller connected to both of said first and second motor drive inverters to distribute power between said first and second sources of DC electric power by modulating torque demands of the two motor drive inverters, and wherein only said further motor drive inverter is bi-directional for providing regeneration during braking.

11. The apparatus of claim 10 in which said first source of DC power is a battery pack.

12. The apparatus of claim 10 in which said second source of DC power is an ultra-capacitor bank.

13. The apparatus of claim 11 in which said second source of DC power is an ultra-capacitor bank.

14. The apparatus of claim 13 in which said controller and associated data bus connected to both said inverters contain basic operational parameters providing an interface to a vehicle or machine in which said apparatus is incorporated.

15. The apparatus of claim 14 in which said apparatus provides drive in a vehicle whereby said second power system is utilized for acceleration of said vehicle and for regeneration of said ultra-capacitor pack in said second power system during vehicle braking periods.

16. The apparatus of claim 10 wherein said first and send AC electric motors being mechanically coupled together to operate on a common load are instead coupled mechanically through a gear-set and an electrically controlled clutch for more efficient operation.

17. Apparatus for sharing power from multiple DC electric power sources in a series or parallel hybrid vehicle comprising:

an AC electric propulsion drive motor;

a first battery pack connected to said AC motor through an inverter;

at least one further battery pack connected to said AC motor through at least one further inverter and an AC line filter;

an internal combustion engine powering a DC generator;

a third inverter accepting DC power from said DC generator and connected to said AC motor through an AC line filter;

an ultra-capacitor bank connected to said AC motor through a bi-directional inverter and an AC line filter; and

a controller responsive to vehicle power demands sharing the power load of said AC motor among all four DC input power sources.

18. The apparatus of claim 17 wherein said apparatus operates without the use of a DC to DC converter.