Vehicle-to-vehicle charging box and method for direct current fast charging using same

Abstract

A vehicle-to-vehicle charging box and a method for direct current fast charging using the same are disclosed. The charging box performs a direct current fast charge (DCFC) session of a recipient by a supplier, for example during a vehicle-to-vehicle (V2V) charging session, and includes: a portable housing; a disconnection device connected to a high voltage (HV) bus to connect or disconnect the respective inlet and outlet charging ports with or from the bus; and a plurality of direct current to direct current (DC-DC) converters. A high voltage to high voltage (HV-HV) converter is connected to the bus. An optional high voltage to low voltage (HV-LV) converter may be connected to the HV-HV converter. An optional low voltage (LV) energy storage device is connected to the housing and the HV-LV converter. A communication processing unit (CPU) establishes bidirectional communication between a supplier and a receiver. The system controller selectively pre-charges the bus, recharges the energy storage device, and selectively commands unloading of the DC charging current from the supplier through the HV-HV converter and to the recipient.

Description

Background Art

[0001] Plug-in hybrid electric vehicles, all-electric vehicles, and extended-range electric vehicles, collectively referred to herein as EVs for simplicity, are equipped with an electrified powertrain system. One or more electric traction motors of the electrified powertrain system are powered by controlled discharge of a high-voltage traction battery pack. The powered traction motors generate output torque, which in turn is directed to one or more road wheels of the EV. The EV is thus propelled along a road surface due to the electrically driven rotation of the road wheels.

[0002] The constituent electrochemical cells of a typical EV's depleted traction battery pack may be selectively recharged using an off-board plug-in charging process, with some of the battery packs also being recharged via regenerative braking or other regenerative functions during EV operation. As is appreciated in the art, off-board charging requires the battery pack to be electrically connected to an alternating current (AC) or direct current (DC) electric vehicle supply equipment (EVSE) charging station via a charging cable. After the communication and control circuitry of the charging station and the EV establishes bidirectional communication according to an appropriate charging protocol, the charging station offloads charging current to the depleted battery pack to thereby charge the individual cells of the battery pack to a threshold state of charge or voltage capability. Summary of the invention

[0003] Disclosed herein is a portable charging circuit accessory, hereinafter referred to for simplicity as a charging box, and a corresponding method for performing charging operations between a charge providing system ("donor") and a charge receiving system ("recipient") using the charging box. The underlying charging architecture, circuitry, and charging strategies described in detail herein enable high voltage energy transfer to occur between a donor system and a recipient system (e.g., a full battery electric vehicle or plug-in hybrid electric vehicle (EV)) or potentially between two battery electric systems in a non-EV extension of the present teachings.

[0004] In a particular embodiment, a charging box for performing a direct current fast charging (DCFC) session of a recipient by a supplier includes: a portable housing having an inlet charging port and an outlet charging port connectable to the supplier and the recipient, respectively. The charging box also includes: a high voltage (HV) bus; a first set of HV disconnect devices and a second set of HV disconnect devices connected to the HV bus and configured to connect or disconnect the corresponding inlet charging port and outlet charging port to the HV bus; and one or more direct current to direct current (DC-DC) converters connected to the portable housing. (Multiple) DC-DC converters include a high voltage to high voltage (HV-HV) converter connected to the HV bus, and in some embodiments also include a high voltage to low voltage (HV-LV) converter connected to the HV-HV converter.

[0005] Additionally, an optional low voltage (LV) energy storage device, when used, can be connected to the portable housing and the HV-LV converter noted above, or the charging box can be connected to an available 12V power source on a vehicle in a host system such as this. A communications processing unit (CPU) is configured to establish and maintain bidirectional communications between the donor and recipient during a DCFC charging session. The system controller is configured during a DCFC charging session to: selectively pre-charge the HV bus between the inlet charging port and the HV-HV converter if necessary, recharge the optional LV energy storage device when such a device is used, and selectively command a discharge of DC charging current from the donor's battery pack through the HV-HV converter and to the recipient's battery pack.

[0006] The portable housing in one or more embodiments defines a housing volume. In such instances, the HV-HV converter, CPU and system controller together form part of a charging circuit located within the housing volume.

[0007] The first and second sets of HV disconnect devices may include first and second sets of HV contactors connected to the inlet charging port and the outlet charging port by corresponding fuses.

[0008] The optional LV energy storage device may include a 12-15 volt battery pack or a 12-15 volt ultracapacitor or supercapacitor in one or more embodiments.

[0009] The HV-HV converter may be configured as a buck-boost converter.

[0010] One aspect of the present disclosure includes a human machine interface (HMI) connected to a portable housing. The HMI is configured to receive user input to a system controller during a DCFC session and to display information related to the DCFC session.

[0011] The charging case may further include a thermal management system operable to regulate the temperature of the plurality of DC-DC converters.

[0012] The aforementioned CPU includes: a corresponding communication stack for the supplier and the receiver; and an application layer connected to the communication stack to facilitate two-way communication between the supplier and the receiver.

[0013] The system controller, for its part, may quantify the DCFC charging session upon completion as a quantified session, generate a charging summary for the DCFC charging session based on the quantified session, and transmit the charging summary to a user of the recipient. The system controller may also optionally execute an adaptive self-learning algorithm to analyze the charging behavior of the recipient group from previous DCFC charging sessions, and adjust the performance of the charging box over time based on the charging behavior.

[0014] The recipient and the donor may both be configured as battery electric vehicles or plug-in hybrid electric vehicles, in which case the DCFC charging session noted above is a vehicle-to-vehicle charging session.

[0015] Also disclosed herein is a vehicle-to-vehicle (V2V) charging box for performing a DCFC session of charging a receiving vehicle ("recipient") by a charging providing vehicle ("provider"). The V2V charging box may include a portable housing that defines a housing volume and includes an inlet charging port and an outlet charging port that are connectable to the supplier and the recipient, respectively. The V2V charging box also includes: an HV bus; a first HV contactor set and a second HV contactor set that are connected to the HV bus; and an HV-HV converter that is connected to the HV bus. The HV-HV converter is configured to output a charging power of at least approximately 50 kilowatts (kW).

[0016] The V2V charging box in this embodiment also includes: a thermal management system operable to regulate the temperature of the HV-HV converter; and a communication processing unit (CPU) configured to establish and maintain bidirectional communication between the supplier and the receiver during the DCFC charging session. The CPU includes: corresponding communication stacks for the supplier and the receiver; and an application layer connected to the communication stack to facilitate bidirectional communication between the supplier and the receiver.

[0017] As part of this embodiment, the system controller is configured during a DCFC charging session to: selectively pre-charge the HV bus between the inlet charging port and the HV-HV converter, recharge the optional LV energy storage device when used, and selectively command a discharge of DC charging current from a donor battery pack through the HV-HV converter and to a recipient battery pack. The high voltage bus, the first and second HV contactor sets, the (multiple) DC-DC converters, the CPU, and the system controller are located within the housing volume.

[0018] A V2V charging method is also disclosed herein, an embodiment of which includes: detecting, via its system controller, predetermined electrical connections of a supplier and a receiver to a V2V charging box. The predetermined electrical connections include connections of the supplier and the receiver to an inlet charging port and an outlet port of a portable housing of the V2V charging box, respectively. The method also includes: establishing bidirectional communication between the supplier and the receiver using a communication processing unit (CPU) of the V2V charging box, wherein the CPU is connected to a LV energy storage device within the V2V charging box. The CPU includes: corresponding communication stacks for the supplier and the receiver; and an application layer, which is connected to the communication stack to facilitate bidirectional communication.

[0019] During a V2V charging session, the method includes: commanding the HV-LV converter of the V2V charging box via a system controller of the V2V charging box to pre-charge the HV bus between the inlet charging port of the V2V charging box and the HV-HV converter; selectively recharging the LV energy storage device via the HV-LV converter; and unloading the DC charging current from a battery pack of a supplier across a first set of contactors of the V2V charging box, through the HV-HV converter, across a second set of contactors of the V2V charging box and to a battery pack of a recipient, thereby performing a V2V charging session.

[0020] According to one aspect of the present invention, a charging box for performing a direct current fast charging (DCFC) session of a charging receiving system ("receiver") by a charging providing system ("provider"), the charging box comprising:

[0021] a portable housing having an inlet charging port and an outlet charging port connectable to a donor and a recipient, respectively;

[0022] High voltage (HV) bus;

[0023] a first set of HV disconnect devices and a second set of HV disconnect devices connected to the HV bus and configured to respectively connect or disconnect the corresponding inlet charging port and outlet charging port to the HV bus;

[0024] at least one direct current to direct current (DC-DC) converter connected to the portable housing, including a high voltage to high voltage (HV-HV) converter connected to the HV bus;

[0025] a communication processing unit (CPU) connectable to the low voltage energy storage device and configured to establish and maintain bidirectional communication between the supplier and the receiver during a DCFC charging session; and

[0026] A system controller is configured to selectively pre-charge an HV bus between an inlet charging port and an HV-HV converter and selectively command a discharge of DC charging current from a donor battery pack through the HV-HV converter and to a recipient battery pack during a DCFC charging session.

[0027] A charging case as described above, wherein the portable housing defines a housing volume, and wherein the at least one DC-DC converter, the CPU, and the system controller collectively form a charging circuit located within the housing volume.

[0028] As in the aforementioned charging box, the first HV disconnect device set and the second HV disconnect device set include a first HV contactor set and a second HV contactor set connected to the inlet charging port and the outlet charging port through corresponding fuses.

[0029] The charging box as described above further comprises:

[0030] LV energy storage device, wherein the at least one DC-DC converter includes a high voltage to low voltage (HV-LV) converter connected to the HV-HV converter, a low voltage (LV) energy storage device connected to the portable housing and the HV-LV converter, and wherein the system controller is configured to recharge the LV energy storage device via the HV-LV converter.

[0031] As in the aforementioned charging box, the LV energy storage device comprises a 12-15 volt battery pack, an ultracapacitor or a supercapacitor.

[0032] As in the aforementioned charging box, wherein the HV-HV converter is a buck-boost converter.

[0033] The charging box as described above further comprises:

[0034] A human machine interface (HMI) is connected to the portable housing, wherein the HMI is configured to receive user input to the system controller during the DCFC session and to display information related to the DCFC session.

[0035] The charging box as described above further comprises:

[0036] A thermal management system is operable to regulate the temperature of a plurality of DC-DC converters.

[0037] The charging box as described above, wherein the CPU includes: corresponding communication stacks for the supplier and the receiver; and an application layer connected to the communication stack to facilitate two-way communication between the supplier and the receiver.

[0038] The charging box as described above, wherein the system controller is configured to: quantify the DCFC charging session into a quantified session upon completion, generate a charging summary for the DCFC charging session based on the quantified session, and transmit the charging summary to a recipient user.

[0039] The charging box as described above, wherein the system controller is configured to: execute an adaptive self-learning algorithm to analyze charging behavior of a group of recipients from previous DCFC charging sessions, and adjust performance of the charging box over time based on the charging behavior.

[0040] A charging box as previously described, wherein both the recipient and the donor are configured as battery electric vehicles or plug-in hybrid electric vehicles, and wherein the DCFC charging session is a vehicle-to-vehicle charging session.

[0041] According to another aspect of the present invention, a vehicle-to-vehicle (V2V) charging box for performing a direct current fast charging (DCFC) session of a charging receiving vehicle (“recipient”) by a charging providing vehicle (“provider”), the V2V comprising:

[0042] a portable housing defining a housing volume, the portable housing having an inlet charging port and an outlet charging port connectable to a donor and a recipient, respectively;

[0043] High voltage (HV) bus;

[0044] a first set of HV contactors and a second set of HV contactors connected to the HV bus and configured to connect or disconnect the corresponding inlet charging port and outlet charging port to the HV bus;

[0045] a high-voltage-to-high-voltage (HV-HV) converter connected to the HV bus and configured to output at least approximately 50 kilowatts (kW) of charging power;

[0046] a thermal management system operable to regulate the temperature of the HV-HV converter;

[0047] a communication processing unit (CPU) configured to establish and maintain bidirectional communication between a supplier and a receiver during a DCFC charging session, wherein the CPU comprises: corresponding communication stacks for the supplier and the receiver; and an application layer connected to the communication stack to facilitate the bidirectional communication between the supplier and the receiver; and

[0048] A system controller configured to selectively pre-charge an HV bus between an inlet charging port and an HV-HV converter during a DCFC charging session, and selectively command a DC charging current to be unloaded from a supplying battery pack through the HV-HV converter and to a receiving battery pack, wherein the high voltage bus, a first set of HV contactors and a second set of HV contactors, the HV-HV converter, a CPU, and the system controller are located within a housing volume.

[0049] The V2V charging box as mentioned above further comprises:

[0050] a high voltage to low voltage (HV-LV) converter connected to the HV-HV converter; and

[0051] A low voltage (LV) energy storage device is connected to the portable housing and the HV-LV converter, wherein the system controller is configured to recharge the LV energy storage device via the HV-LV converter.

[0052] The V2V charging box as mentioned above further comprises:

[0053] A human machine interface (HMI) connected to the portable housing, wherein the HMI is configured to: receive user input to the system controller during the V2V charging process and display information related to the V2V charging process, wherein the system controller is configured to: quantify the completion of the DCFC charging session into a quantified session, generate a charging summary for the DCFC charging session based on the quantified session, and transmit the charging summary to a recipient user via the HMI.

[0054] The V2V charging box as described above, wherein the system controller is configured to: execute an adaptive self-learning algorithm to analyze charging behavior of a group of recipients from previous DCFC charging sessions, and adjust the performance of the charging box over time based on the charging behavior.

[0055] According to yet another aspect of the present invention, a vehicle-to-vehicle (V2V) charging method includes:

[0056] Detecting predetermined electrical connections of a charge providing vehicle ("Donor") and a charge receiving vehicle ("Recipient") via their system controllers to a vehicle-to-vehicle (V2V) charging box, the predetermined electrical connections comprising connections of the Donor and Recipient to an inlet charging port and an outlet port of a portable housing of the V2V charging box, respectively;

[0057] establishing bidirectional communication between a donor and a recipient using a communication processing unit (CPU) of the V2V charging box, the CPU being connected to a low voltage (LV) energy storage device within the V2V charging box, wherein the CPU includes: corresponding communication stacks for the donor and the recipient; and an application layer connected to the communication stack to facilitate the bidirectional communication; and

[0058] During a V2V charging session:

[0059] commanding, via a system controller of the V2V charging box, a high voltage to low voltage (HV-LV) converter of the V2V charging box to pre-charge an HV bus between an inlet charging port of the V2V charging box and a high voltage to high voltage (HV-HV) converter;

[0060] selectively recharging the LV energy storage device via the HV-LV converter; and

[0061] A DC charging current is unloaded from a donor's battery pack across a first set of contactors of the V2V charging box, through an HV-HV converter across a second set of contactors of the V2V charging box, and to a recipient's battery pack to thereby perform a V2V charging session.

[0062] The method as above further comprises:

[0063] During a V2V charging session, the temperature of the HV-HV converter and the HV-LV converter are regulated via a thermal management system of the V2V charging box.

[0064] The method as above further comprises:

[0065] quantifying, via the system controller, the V2V charging session into a quantified session upon completion of the V2V charging session;

[0066] generating a charging summary for the V2V charging session based on the quantified session; and

[0067] Transmits the charging summary to the recipient's user.

[0068] The method as above further comprises:

[0069] executing an adaptive self-learning algorithm to thereby analyze charging behavior of the recipient group from previous DCFC charging sessions; and

[0070] Adjust the performance of the V2V charging box over time based on charging behavior.

[0071] The above features and advantages and other features and attendant advantages of the present disclosure will be readily apparent from the following detailed description of illustrative examples and modes for carrying out the present disclosure when considered in conjunction with the accompanying drawings and appended claims. In addition, the present disclosure expressly includes combinations and sub-combinations of the elements and features set forth above and below. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Figure 1 is an illustration of a representative direct current fast charging (DCFC) charging session between a charge providing vehicle (“donor”) and a charge receiving vehicle (“recipient”) using the charging box disclosed herein.

[0073] Figure 2 Graphics Figure 1 Simplified connection of the charging box.

[0074] Figure 3 Depiction Figure 1 and Figure 2 A representative embodiment of a charging case is shown in FIG.

[0075] Figure 4A , Figure 4B and Figure 4C Commonly formed description for use during a representative V2V charging session Figures 1 to 3 A flow chart of a method for charging a charging box.

[0076] The present disclosure may be modified or embodied in alternative forms, wherein representative embodiments are shown in the accompanying drawings and described in detail below. The innovative aspects of the present disclosure are not limited to the disclosed embodiments. On the contrary, the present disclosure is intended to cover alternatives that fall within the scope of the present disclosure as defined by the appended claims. DETAILED DESCRIPTION

[0077] Referring to the drawings, wherein like reference numerals refer to like features throughout the several views, Figure 1 A direct current fast charging (DCFC) operation in the form of a representative vehicle-to-vehicle (V2V) charging session 10 is depicted. During the V2V charging session 10, a charge-providing electric vehicle (EV), hereinafter referred to as a supplier 12D for simplicity, offloads a high-voltage direct current (DC) charging current (DC-1) to a charging box 14, which is hereinafter referred to as a V2V charging box, rather than limiting the present teachings to vehicle-based charging applications. The V2V charging box 14 in turn delivers a DC charging current (DC-2) to a charging receiving electric vehicle (i.e., a recipient 12R). From the perspective of the recipient 12R, the supplier 12D and the V2V charging box 14 appear together as an off-board electric vehicle supply equipment (EVSE) DCFC charging station of the type indicated above. However, in contrast to an off-board EVSE charging station capable of providing DCFC functionality, the portability and configured functionality of the V2V charging box 14 described below also provide owners / operators of EVs and other electrified systems with the benefits of enhanced charging mobility and reduced range anxiety, in addition to other attendant benefits.

[0078] The supplier 12D and the receiver 12R contemplated herein include a main body 13D, 13R and a corresponding electric powertrain system 50D and 50R. In a typical configuration, the supplier 12D includes a charging port 16 that is connected to a high voltage (HV) electrochemical traction battery pack (B) via an onboard DCFC contactor 20. HV ) 18. The battery pack 18 is in turn connected to a power inverter module (PIM) 22. In a discharge mode of the battery pack 18, the battery pack 18 delivers a DC voltage (VDC) to the DC side of the PIM 22. The PIM 22 is driven by pulse width modulation or other suitable switch control techniques using ON / OFF conduction state control of a plurality of solid-state semiconductor switches (not shown) such as IGBTs, MOSFETs, thyristors, etc.

[0079] The switching control of the PIM 22 ultimately converts the DC input voltage from the battery pack 18 into a voltage suitable for powering the electric traction motor (M). E ) 24, thereby causing the machine to rotate. The output torque (arrow T) from the electric traction motor 24 O) is then delivered to one or more road wheels 26 of the supplier 12D. Figure 1 The receiver 12R shown in FIG. 1 may be similarly or identically configured to include a corresponding charging port 116, a traction battery pack 118, a DCFC contactor 120, a PIM 122, and an electric traction motor 124. Thus, in addition to being equipped to perform Figure 1 In addition to the V2V charging session 10 , the respective electric powertrain systems 50D and 50R are also configured to electrically propel the corresponding donor 12D and recipient 12R during the split conduction discharge mode of the battery packs 18 and 118 .

[0080] Brief reference Figure 2 , the following situation may occur during operation of the recipient 12R: the traction battery pack 118 may become depleted of charge, at least to the extent that the owner / operator of the recipient 12R requires charging. When this situation occurs, the recipient 12R may not be in the vicinity of an available EVSE charging station or a home or office charging station. In such a situation, the same owner / operator in accordance with the present teachings may request to perform a V2V charging session 10 as a mobile DCFC charging session. During this event, the portable V2V charging box 14 may, for example, be transported to the site of the recipient 12R via the supplier 12D or another vehicle, and thereafter connected to the supplier 12D and the recipient 12R via the charging cable 30 and the charging ports 16, 116, as described below. The charging ports 16 and 116 may be variously configured to receive SAE J1772, National Charging Standard (NACS), Combined Charging System (CCS), CHAdeMO, or other suitable charging connectors depending on the embodiment, and are therefore generally shown in Figure 1 and Figure 2 middle.

[0081] As is understood in the art and noted above, the supplier 12D and the recipient 12R are equipped with the above noted traction battery packs 18 and 118, respectively. Additionally, the supplier 12D will include an onboard vehicle controller 32 (C D ), which has one or more processors (P) 36, memory (M) 38 and embodies FIG. 4A to FIG. 4C The receiving party 12R is similarly equipped with a vehicle controller 132 (C R), (multiple) processors (P) 136 and memory (M) 138, with corresponding versions of the instruction set 100S. Thus, the donor 12D and the recipient 12R are equipped to communicate via the exchange of data during the V2V session 10, manage and coordinate power flow, monitor the correct connection and other conditions / error states of the charging cable 30, regulate the temperature of the V2V charging box 14, and perform other related functions during the V2V charging session 10, as described below.

[0082] To perform the functions of the present method 100, such as by executing one or more algorithms and automated and / or manual processing steps set forth below, such functions may be embodied computer readable instructions (i.e., instruction set 100S) from a tangible, non-transitory computer readable storage medium portion of the associated memory 38 and 138. For example, the memory 38 and 138 may include magnetic or optical media, CD-ROMs, and / or solid-state / semiconductor memory (e.g., various types of RAM or ROM). The term "vehicle controller" and related terms (such as control module, control unit, processor, and similar terms) may refer to one or various combinations of associated non-transitory memory components in the form of application specific integrated circuit(s) (ASICs), field programmable gate arrays (FPGAs), electronic circuit(s), central processing unit(s) (e.g., microprocessor(s)), and memory and storage devices (read-only, programmable read-only, random access, hard disk drives, etc.). As used herein, the non-transitory components of memory 38 and 138 are capable of storing machine-readable instructions in the form of one or more software or firmware programs or routines, (multiple) combinational logic circuits, (multiple) input / output circuits and devices, signal conditioning and buffering circuits, and other components that can be accessed by one or more processors 34 and 134 to provide the described functionality.

[0083] Still refer to Figure 2 , the V2V charging box 14 contemplated herein is configured in a representative embodiment to output a rated charging power of at least approximately 50-100 kilowatts (kW) of continuous power and approximately 150-300 amperes (A) of continuous output current. In a possible configuration, the V2V charging box 14 can receive approximately 350-1000V or more from the supplier 12D, and in response thereto, can output approximately 150-1000V or more to the recipient 12R, where other voltage ranges are possible depending on the embodiment. The V2V charging box 14 is also configured with buck / boost capability so that the V2V charging box 14 can reduce (buck) or increase (boost) the DC voltage ( Figure 1DC-1), where the V2V charging box 14 performs this operation based on the state of charge (SOC) or voltage capability of the traction battery pack 118 of the recipient 12R, the amount of power requested, the power capability / SOC / voltage capability of the supplier 12D, and other factors.

[0084] Now refer to Figure 3 , the mobile plug-in DCFC functionality contemplated herein involves coordinated bidirectional communication of data between the supplier 12D and the receiver 12R. The data exchange takes the form of a low voltage control pilot or communication (Comms) signal typically in the range of 0-12V and a proximity voltage (Prox) signal of 0-5V. An electrical ground (GND) is also provided. For example, the established J1772 connection allows the respective processors of the supplier 12D and the receiver 12R to communicate with each other using power line communication (PLC) for comms signals, which in turn proceed according to the established communication protocol via coordinated exchange of data messages. The comms signal is often used to verify the connection between the non-board EVSE charging station and the charging EV (whose corresponding position is occupied by the supplier 12D and the V2V charging box 14 (together acting as such an EVSE charging station)) and the receiver 12R to transmit the charging status. This situation may occur, for example, using a fixed duty cycle during the envisioned DC charging. The same signal can be used to adjust the charging rate as needed. Other standards (such as NACS, CCS, CHAdeMO, etc. noted above) may be used in a similar fashion, and thus the specific charging standard may vary depending on the desired end use.

[0085] The multi-pin charging plug 30C of the deployed charging cable 30 is connected to corresponding charging ports of the charging ports 16, 116 located on the donor 12D and the recipient 12R, respectively (see Figure 1 ). In accordance with the relevant charging protocol, the DC charging power is fed through the conductive pins of the charging port 16 of the donor 12D, across the V2V charging box 14 and into the traction battery pack 118 of the recipient 12R. Figure 2 The exchange of data / messages between the processor 36 of the donor 12D, the processor or system controller 61 of the V2V charging box 14, and the corresponding processor 136 (e.g., a battery management system or another battery controller) of the recipient 12R coordinates the DCFC charging process. The comms and proximity signals noted above are exchanged between the processors 36, 136, and 61, wherein the general process of DC charging under DIN 70121 or other related protocols is well understood in the art. Also as understood in the art, such protocols proceed according to a defined multi-step electronic "handshake" process before permitting the transfer of energy, wherein the process is also noted below in the description of the method 100.

[0086] V2V charging box content: configured to function as a DCFC accessory for performing V2V charging events / sessions Figure 2 The V2V charging box 14 illustrated in the figure may include a portable housing 40 (e.g., a weatherproof, rugged, and sufficiently lightweight enclosure constructed of molded plastic, aluminum, steel, etc.). The portability of the housing 40 may be facilitated by connecting or securing wheels and / or a handle (not shown) to the housing 40. The housing 40 is also connected to respective inlet charging ports 42 and outlet charging ports 142, which in turn may be connected to the donor 12D and the recipient 12R, respectively, during the V2V session 10.

[0087] The housing 40 defines a housing volume 400. One or more direct current to direct current (DC-DC) converters are disposed in the housing volume 400 and connected to the housing 40 for safe transport and operation. Figure 3 In the illustrated embodiment, such a converter includes a high voltage to high voltage (HV-HV) converter 44 (e.g., an HV buck-boost converter) and a high voltage to low voltage (HV-LV) converter 46. An optional LV energy storage device 48 (e.g., an electrochemical battery pack, an ultracapacitor, or a supercapacitor in different implementations) can be connected to the low voltage side of the HV-LV converter 46 as shown, or the LV power supply can be provided separately, for example, via a plug-in connection to an onboard / onboard 12-15V power supply. The optional LV energy storage device 48 is also electrically connected to the HV-HV converter 44 when used to provide a low voltage (e.g., nominal 12-15V) power supply suitable for opening / closing the HV disconnect devices 62 and 162 and powering the voltage or current sensor 63 and associated circuits and diagnostic components. The connection of the LV energy storage device 48 and the HV-LV converter 46 also enables the HV-LV converter 46 to selectively charge the LV energy storage device 48 during the V2V charging session 10. The optional LV energy storage device 48 may also be recharged in certain configurations via AC mains power, for example, by plugging the housing 40 into an available wall socket via a corresponding charging outlet 49 disposed thereon. Use of such an AC outlet 49 would enable the LV energy storage device 48 to be charged from a wall connection adapter / AC outlet (not shown) in the supplier 12D, which may be particularly useful when the V2V charging box 14 has been idle for an extended period of time between V2V charging sessions 10.

[0088] Figure 3The V2V charging box 14 illustrated in FIG. 1 also includes a communication processing unit (CPU) 55 operable to establish and maintain bidirectional communications between the donor 12D and the recipient 12R during the V2V charging session 10. Separate communication circuits / stacks or "comm stacks" 58 and 158 (Comm S) may be included in the CPU 55, with an application layer 60 disposed therebetween to coordinate wired / wireless data exchanges. Figure 3 The comm stacks 58 and 158 in the non-limiting embodiment may include different connections and components (e.g., a ground (GND) connection 59A, an SAE J1772 PWM block 59B, and a PLC processor 59C for the comms stack 58) or equivalent structures in other embodiments, and corresponding ground connections 159A, PWM blocks 159B, and processing 159C for the comms stack 158.

[0089] To this end, during the V2V charging session 10, the CPU 55 may be configured to coordinate the processors 36 and 136 noted above of the respective donor 12D and recipient 12R. Communication is via one or more communication modules connected to / available for the application layer 60 (e.g., BLE / WiFi / LTE software module 60A, ISO-20 communication software module 60B, DIN communication software module 60C, and ISO-3 communication software module 60D, as shown in FIG. Figure 3 As is appreciated in the art, such software is typically used during EV charging to facilitate the wireless exchange of data, and is therefore well understood in the art.

[0090] Using the comms stack 58 and 158, the application layer 60 and the associated software modules 60A, 60B and 60C, the CPU 55 can command the HV-LV converter 46 to pre-charge the HV bus 56 of the V2V charging box 14 to a level equal to the level of the HV bus on the supplier 12D, and selectively recharge the LV energy storage device 48 via the HV-LV converter 46 as needed. Figure 2 The CPU 55 of the processors 36 and 136 closely coordinates to selectively command DC charging through the operation of the HV-HV converter 44 from Figure 1 and Figure 2The unloading of the traction battery pack 18 of the donor 12D to the traction battery pack 118 of the recipient 12R. The DC-DC converter(s) (i.e., HV-HV converter 44 and optional HV-LV converter 46) together with the optional LV energy storage device 48, CPU 55, system controller 61 and associated hardware and software together form the V2V charging circuit 14C located within the housing volume 400, wherein the system controller 61 for its part includes one or more processors, memory and other hardware specified above.

[0091] Still refer to Figure 3 , the V2V charging box 14 and its resident charging circuit 14C respectively include a first HV disconnect device set 62 and a second HV disconnect device set 162. The HV-HV converter 44 is connectable to the positive and negative HV rails (+, -) between the inlet charging port 42 and the outlet charging port 142 via the first HV disconnect device set 62 and the second HV disconnect device set 162, respectively. A fault isolation device 57 (such as a fuse, a pyrotechnic switch, or an electronic fuse) may be arranged as shown to provide additional high voltage protection.

[0092] Other components of the V2V charging box 14 may include a human machine interface (HMI) 70 that is connected to the portable housing 40 and is configured to Figures 1 to 3 The HMI 70 may be configured to facilitate interactive machine interaction during the course of a V2V session 10 of the V2V charging box 14. The HMI 70 may receive user input to the system controller 61 during the V2V charging session 10 and display information related to the V2V charging session 10 for viewing by a user of the V2V charging box 14. For example, the HMI 70 may include one or more display screens, alphanumeric touch screens, button keypads, and / or other peripheral devices that present prompts and sequential instructions for the owner / operator to follow. The HMI 70 may also present information to the user(s), such as the current communication and charge dump status of the V2V session 10, the SOC, voltage, or other status of the respective donor 12D and recipient 12R traction battery packs 18 and 118, the charging time and dump power totals, etc. A controller area network (CAN) bus may be included in the architecture of the V2V charging box 14 to communicate between various modules or devices using low voltage differential signals.

[0093] Additionally, a thermal management system (TMS) 72 may be incorporated into or connected to the V2V charging box 14 to regulate the temperature of the high voltage and other components contained therein, particularly the HV-HV converter 44 and the optional HV-LV converter 46. By way of example and not limitation, the thermal management system 72 may include a heat sink having an electrically conductive and / or forced convection device (e.g., a cooling plate, a fan, etc., a fluid device such as a coolant loop / pump, a cooling blanket, etc.). In some implementations, the thermal management system 72 may include an optional phase change material to optimize mass, instantaneous heat removal capabilities, etc.

[0094] In general, the method 100 described below includes: detecting a predetermined electrical connection between the donor 12D and the recipient 12R via their system controllers 61 to the charging box 14, wherein the predetermined electrical connection includes the donor 12D and the recipient 12R connecting to the charging box 14. Figure 3 4 and 5. The method 100 also includes establishing bidirectional communication between the donor 12D and the recipient 12R using the CPU 55 of the charging box 14 described above. During the V2V charging session 10, the method 100 may include commanding the HV-LV converter 46 (when used) via the system controller 61 of the charging box 14 to pre-charge the HV bus 56 between the inlet charging port 42 and the HV-HV converter 44, and selectively recharging the optional LV energy storage device 48 via the HV-LV converter 46. The method 100 may also include causing the DC charging current to be unloaded from the battery pack 18 of the donor 12D across the first disconnect device set 62 (e.g., the HV contactor of the charging box 14), across the second disconnect device set 162 of the charging box 14 through the HV-HV converter 44, and to the battery pack 118 of the recipient 12R to thereby perform the V2V charging session 10. Gate drive signals, mode control signals, and controller area network (CAN) messages may be used by the system controller 61 for such purposes, such as in Figure 3 Now we will refer to FIG. 4A to FIG. 4C Describes a more specific implementation.

[0095] Reference Figure 4A , Figure 4B and Figure 4C , these three figures collectively represent an embodiment of method 100 using discrete processing steps, segments, or blocks for clarity. Each component block of method 100 can be implemented in the order set forth herein to use Figure 3 The hardware performs a V2V charging session 10.

[0096] First refer to Figure 4A , method 100 is to Figures 1 to 3The request for emergency charging B102 of the charging receiving vehicle or recipient 12R begins at block B102. For example, the owner / operator of the recipient 12R may send a request to the owner / operator of the charging providing vehicle or provider 12D using The V2V charging session is requested via a text message or phone call, or the need or desire for a mobile DCFC event is otherwise signaled. The method 100 then continues to block B104.

[0097] At block B104, the donor 12D arrives on site and parks near the recipient 12R. The donor 12D may in this case pull in front of or beside the recipient 12R to make the charging ports 16 and 116 easily accessible to each other. The method 100 thereafter continues to block B106.

[0098] Figure 4A Block B106 includes: connecting the charging cable 30 to Figures 1 to 3 For example, the charging cable 30 may be a CCS / NACS charging cable as noted above, in which case one end of the cable 30 may be plugged into the charging port 16 on the supplier 12D, and the opposite end of the same cable 30 may be plugged into the inlet charging port 42 on the V2V charging box 14 (see Figure 3 As part of the method 100 described in detail below, it is also possible to Figure 4A Block B113 of the method 100 reaches block B106. Once the charging cable 30 has been securely connected between the donor 12D and the V2V charging box 14, the method 100 continues from block B106 to block B108.

[0099] At block B108, similar to block B106, another charging cable 30 is connected between the outlet charging port 142 of the V2V charging box 14 and the charging port 116 of the recipient 12R. Thus, upon completion of block B108, the donor 12D is electrically connected to the recipient 12R via the intervening V2V charging box 14. The method 100 then continues to block B110.

[0100] Figure 4A Block B110 of the embodiment includes: turning on the V2V charging box 14 so that the V2V charging box is powered by the low voltage power. For example, a soft switch or a hard switch may be activated by a user of the V2V charging box 14 to switch the low voltage power from Figure 3 LV energy storage device 48 or from another 12V power supply to CPU 55 and other low power devices. At the completion of block B110, Figure 4A The method 100 arrives at point A in the illustrated process flow.

[0101] Now refer to Figure 4B , and starts at point A (see Figure 4A ), the method 100 continues to block B112 to start the function of the supplier 12D, and continues to block B117 to start the function of the receiver 12R. Figures 1 to 3 The V2V session 10 of the present invention may be performed by the user. For example, the human machine interface (HMI) 70 of the V2V charging box 14 may be accessed directly or via a portable electronic device such as a smartphone or tablet computer. The user may request to unload the high voltage power from the traction battery pack 18 of the donor 12D, which will then initiate the remaining charging sequence. Upon completion of block B112, the method 100 continues to block B113.

[0102] Block B113 entails determining whether the supplier 12D has received an electronic handshake signal (e.g., a Transport Layer Security (TLS) handshake) from the recipient 12R. As is appreciated in the art, such a handshake signal is generally used to establish an encrypted, two-way communication session between the charging provider and the charging recipient during EV charging. This extends to current DCFC / V2V charging scenarios. The method 100 continues to block B114 when the supplier 12D has received the handshake signal, and continues to block B115 when no handshake signal is detected. Figure 4A Block B106.

[0103] exist Figure 4B At block B114 of , after confirming receipt of the electronic handshake signal at the previous block B113, the receiver 12R transmits its power and current limits to the V2V charging box 14 via the intervening charging cable 30 via the established power line connection. In turn, the V2V charging box 14 transmits the power and current limits of the supplier 12D and the V2V charging box 14 to the receiver 12R, so that the receiver 12R treats the combination of the supplier 12D and the V2V charging box 14 as a single charging unit (i.e., similar to an off-board EVSE charging station). The V2V charging box 14 communicates the power and current limits of the supplier 12D and the V2V charging box 14 to the receiver 12R. Figure 3 The DC bus 56 is precharged in response to a successful handshake. To this end, Figure 3 The HV-LV converter 46 operates in a boost mode such that the internal switching and power conversion operations of the HV-LV converter 46 are used to increase the voltage level of the LV energy storage device 48 to match the high voltage level of the supplier 12D. The method 100 thereafter continues to block B115.

[0104] Block B115 requires determining via the system controller 61 of the V2V charging box 14 the DCFC contactor 20 ( Figure 2 ) is closed and there are Figure 3The method 100 continues to the step of determining whether the first disconnect device set 62 of the V2V charging box 14 of the DCFC contactor 20 or the V2V charging box 14 is also closed. Figure 4A , and alternatively proceeds to block B116 when both the DCFC contactor 20 and the disconnect device 62 are in the closed state.

[0105] When the DCFC contactor 20 on the supplier 12D machine and the first disconnect device set 62 of the V2V charging box 14 are closed, block B116 is executed. In this case, the system controller 61 transitions the HV-LV converter 46 to a voltage reduction "buck" mode to maintain the LV energy storage device 48 at a calibrated low voltage level (e.g., nominal 12-15V as noted above). Once the buck mode has been implemented, the method 100 continues to block B118.

[0106] At block B117, similar to block B113, the system controller 61 of the V2V charging box 14 verifies that a handshake signal has been received from the donor 12D. In this case, the V2V charging box 14 acts as the resident logic of the recipient 12R. The method 100 continues to block B118 when a handshake signal has been received, and continues to block B119 when an expected handshake signal is not detected. Figure 4A Block B106.

[0107] Figure 4B Block B118 of the V2V charging box 14 needs to command the HV-HV converter 44 to match the pre-charge voltage from block B114. Since the specific voltage requirements of the receiving party 12R may vary for a given charging event, the HV-HV converter 44 in block B118 can function in buck mode (voltage increase) or boost mode (voltage reduction) as needed. The method 100 then continues to block B120.

[0108] At block B120, the DCFC contactor 120 of the recipient 12R is verified as having been closed in a process step similar to the process step performed in block B115. In response thereto, the method 100 continues to block B122. The method 100 otherwise repeats block B117.

[0109] At block B122, energy transfer processing is initiated in response to the aforementioned processing steps. Figure 2 The system controller 61 working in conjunction with the controllers 32 and 132 commands the high voltage DC charge to be unloaded from the traction battery pack 18 of the supplier 12D through the intervening V2V charging box 14 and to the traction battery pack 118 of the recipient 12R. Block B122 may also be from Figure 4C Block B129 is reached, as described below. As the process continues, method 100 continues to blocks B124 and B126.

[0110] Figure 4B Blocks B124 and B126 of FIG. 12A entail discharging the traction battery pack 18 of the donor 12D and charging the traction battery pack 118 of the recipient 12R, respectively. The method 100 thus reaches point B in the illustrated process flow.

[0111] Now refer to Figure 4C , and starting at point B, the method 100 continues to block B125. Here, the CPU 55 and / or other involved circuitry of the donor 12D and recipient 12R scans for cable / disconnection errors. Such errors may occur if any of the charging cables 30 should become loose or disconnected. In the event that such an error is detected, the method 100 continues to block B132. In the absence of such an error, the method 100 instead continues to block B127.

[0112] At block B127, Figure 3 The system controller 61 verifies whether the respective states of charge (SOC) of the donor 12D and the recipient 12R have reached predetermined SOC limits. If so, the method 100 continues to block B128, otherwise the method 100 continues to block B129.

[0113] Block B128, which is reached when the SOC of either the donor 12D or the recipient 12R reaches the predetermined SOC limit of block B127, includes terminating the DCFC charging event from the standpoint of the recipient 12R. This may require sending the necessary signal from the comms stack 158 to the V2V charging box 14 indicating that the recipient 12R no longer requires charging. As part of block B128, the system controller 61 may command the disconnect device 162 to open, thereby interrupting the high voltage connection between the V2V charging box 14 and the recipient 12R. On the recipient 12R machine, Figure 1 The DCFC contactor 120 is also commanded to open. The method 100 then continues to block B130.

[0114] At block B129, the system controller 61 of the V2V charging box 14 next determines whether the user has requested to terminate the V2V session 10. For example, the owner / operator of the donor 12D or recipient 12R may request to terminate the V2V session 10 via wireless or HMI-based communication with the CPU 55 (e.g., via Figure 3 The user may communicate a desire to stop the V2V charging session 10 via the HMI 70 and / or via the app, as noted above. When the user requests that the V2V charging session 10 should be terminated, the method 100 continues to block B128.

[0115] Block B130, similar to block B128, entails terminating the V2V session 10 from the standpoint of the donor 12D. This process is performed in close coordination with the process of block B128 described above. The method 100 thereafter continues to block B136.

[0116] exist Figure 4C At block B132, in response to a cable / disconnection error detected in block B125, Figures 1 to 3 The V2V charging box 14 interrupts its energy transfer to the recipient 12R. The method 100 then continues to block B134.

[0117] Block B134 entails interrupting the handshake signaling described above and terminating the V2V charging session 10. The method 100 thereafter continues to optional block B136.

[0118] Figure 4C Block B136 of may be used in one or more embodiments to quantify the newly completed V2V session 10, and thereafter end the V2V charging session 10 at block B138. For example, the V2V charging box 14 or its use may involve communication with an offline or backend payment system, such as processing of a debit or credit card, use of a mobile payment application accessible via a user device (such as a smartphone or tablet), etc. Cloud connectivity facilitated by a local WiFi connection, long term evolution (LTE), Bluetooth, or other suitable data transfer connection, to offload data describing the V2V session 10 to a backend server to quantify the V2V charging session 10. That is, the system controller 61 may be configured to quantify the V2V charging session 10 upon completion as a quantified session to generate a charging summary for the V2V charging session 10 based on the quantified session. The system controller 61 may then transmit the charging summary to the user of the recipient 12R. This will enable the provider of the mobile DCFC to be compensated for its costs via the V2V charging box 14.

[0119] Similar techniques can also facilitate communication with other vehicles / devices. Figures 1 to 3 The V2V charging box 14 shown in FIG. 1 is assigned a unique alphanumeric identifier, which in turn will allow the backend server noted above to confirm the specific parties involved in the V2V charging session 10. This in turn will enable the party with control over the V2V charging box 14 to thereafter use the established digital payment method to collect or deduct payment for the completed V2V charging session 10. For example, block B 136 may include outputting a summary of the elapsed charging time / duration and / or an invoice therefor, the health status of the traction battery pack 118, the total charging power provided to the recipient 12R, and the associated cost of providing such charging power to the recipient 12R.

[0120] Optionally, the V2V charging box 14 or the backend server noted above may be configured to create a unique charging parameter user profile for a given recipient group 12R (such as similarly equipped EVs). The V2V charging box 14 may use an adaptive self-learning algorithm or other technique to analyze the common charging behavior of such a recipient group 12R from a previous V2V session 10, which will enable the V2V charging box 14 to adjust the performance of the V2V charging box 14 and improve the charging experience for future use. Upon completion of the optional quantification / monetization processing of block B134, method 100 is complete. The LV energy storage device then enters a low power standby mode until the V2V charging box 14 is needed again for a subsequent V2V charging session.

[0121] The mobile DCFC-related hardware and software solutions described above thus provide an electrical architecture that enables energy transfer to occur in a mobile DCFC equipped with a high voltage rechargeable energy storage system (exemplified herein as Figure 1 and Figure 2 Between two EVs or other battery electric systems (of traction battery packs 18 and 118). The foregoing solution speeds up charging relative to the speeds typically associated with AC-based V2V charging or EVSE station-driven DCFC operation. Relative to such alternatives, the portability of the initial self-powered V2V charging box 14 and its configured DCFC capabilities together enable faster, more flexible and user-convenient DCFC charging in V2V situations. In view of the foregoing disclosure, these and other attendant benefits will be readily understood by those skilled in the art.

[0122] The present disclosure allows for many different forms of embodiments. Representative examples of the present disclosure are shown in the accompanying drawings and are described in detail herein as non-limiting examples of the disclosed principles. For this reason, elements and limitations described in the abstract, background technology, summary of the invention, and detailed description but not explicitly set forth in the claims should not be incorporated into the claims individually or collectively by implication, inference, or otherwise.

[0123] For the purposes of this description, unless specifically denied, the use of the singular includes the plural and vice versa, the terms "and" and "or" shall be both conjunctions and transitions, both "any" and "all" shall mean "any and all", and the words "include", "comprising", "including", "having" and the like shall mean "including but not limited to". In addition, approximate words such as "approximately", "almost", "substantially", "generally", "approximately" and the like may be used herein in the sense of "at, close to or nearly", or "within 0-5%", or "within an acceptable manufacturing tolerance", or their logical combinations.

[0124] The detailed description and the accompanying drawings or figures are support and description of the present teaching, but the scope of the present teaching is limited only by the claims. Although some best modes and other embodiments for carrying out the present teaching have been described in detail, there are various alternative designs and embodiments for practicing the present teaching defined in the appended claims. In addition, the present disclosure explicitly includes combinations and sub-combinations of the elements and features set forth above and below.

Claims

1. A charging box for performing a direct current fast charging (DCFC) session of a charging receiving system ("receiver") by a charging providing system ("provider"), the charging box comprising: a portable housing having an inlet charging port and an outlet charging port connectable to a donor and a recipient, respectively; High voltage (HV) bus; a first set of HV disconnect devices and a second set of HV disconnect devices connected to the HV bus and configured to connect or disconnect the corresponding inlet charging port and outlet charging port from the HV bus; a plurality of direct current to direct current (DC-DC) converters connected to the portable housing, the plurality of DC-DC converters comprising: (i) a high voltage to high voltage (HV-HV) converter connected to the HV bus; and (ii) a high voltage to low voltage (HV-LV) converter connected to the HV-HV converter; a low voltage (LV) energy storage device connected to the portable housing and the HV-LV converter; a communication processing unit (CPU) connected to the LV energy storage device and configured to establish and maintain bidirectional communication between the supplier and the receiver during a DCFC charging session; and A system controller configured during a DCFC charging session to: selectively command the HV-LV converter to pre-charge the HV bus between the inlet charging port and the HV-HV converter, recharge the LV energy storage device, and selectively command a discharge of DC charging current from a supplying battery pack through the HV-HV converter and to a receiving battery pack.

2. The charging case of claim 1 , wherein the portable housing defines a housing volume, and wherein the plurality of DC-DC converters, the LV energy storage device, the CPU, and the system controller collectively form a charging circuit located within the housing volume. 3 . The charging box of claim 1 , wherein the first set of HV disconnect devices and the second set of HV disconnect devices include a first set of HV contactors and a second set of HV contactors connected to the inlet charging port and the outlet charging port through corresponding fuses.

4. The charging case of claim 1 , wherein the LV energy storage device comprises a 12-15 volt battery pack. The charging box of claim 1 , wherein the HV-HV converter is a buck-boost converter.

6. The charging box according to claim 1, further comprising: A human machine interface (HMI) is connected to the portable housing, wherein the HMI is configured to receive user input to the system controller during the DCFC session and to display information related to the DCFC session.

7. The charging box according to claim 1, further comprising: A thermal management system is operable to regulate the temperature of a plurality of DC-DC converters.

8. The charging box as claimed in claim 1, wherein the CPU comprises: Corresponding communication stacks for the supplier and receiver; and an application layer, which connects to the communication stack to facilitate bidirectional communication between the supplier and the receiver.

9. The charging box of claim 1, wherein the system controller is configured to: quantify the DCFC charging session upon completion as a quantified session, generate a charging summary for the DCFC charging session based on the quantified session, and transmit the charging summary to a recipient user.

10. The charging box of claim 1, wherein both the recipient and the donor are configured as battery electric vehicles or plug-in hybrid electric vehicles, and wherein the DCFC charging session is a vehicle-to-vehicle charging session.

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