Solid-state fuse with multiple control circuits

Abstract

A solid-state fuse device includes a switch and a gate driver. The gate driver is connected to the switch and configured to switch the switch from a closed state to an open state when at least one of an overcurrent measurement exceeds a predetermined overcurrent threshold or a voltage drop across the switch exceeds a predetermined saturation voltage threshold.

Description

Technical Field

[0001] The present disclosure relates to a fuse, and more particularly, to a resettable solid-state fuse. Background Art

[0002] An electrified vehicle powertrain may include an electrical system having a separate high-voltage bus and a low-voltage bus. Although "high voltage" and "low voltage" are relative terms, "low voltage" may include a maximum voltage level of 12 to 15 volts (i.e., an auxiliary voltage), and the term "high voltage" describes a voltage level that is much higher than the auxiliary voltage level. For example, an electrified vehicle propulsion system may have a maximum bus voltage ranging between 60 volts and 300 volts, and some emerging battery packs have a voltage capacity ranging between 500 volts and 800 volts.

[0003] Strategically located high current fuses and high voltage switches help ensure voltage isolation in the event of a high voltage bus fault, and these switches also open during routine shutdowns. Fuses are circuit elements that can default to an open circuit state in response to a threshold battery pack current. Summary of the invention

[0004] According to several aspects of the present disclosure, a solid-state fuse device includes a switch and a gate driver, wherein the gate driver is connected to the switch and configured to transition the switch from a closed state to an open state when at least one of an overcurrent measurement exceeds a predetermined overcurrent threshold or a voltage drop across the switch exceeds a predetermined saturation voltage threshold.

[0005] In other features, the switch comprises a voltage controlled switching device.

[0006] In other features, the voltage-controlled switch device includes at least one of a silicon insulated gate bipolar transistor (IGBT), a metal-oxide semiconductor field effect transistor (MOSFET), a silicon superjunction MOSFET, a gallium nitride (GaN) field-effect transistor (FET), a SiC junction field-effect transistor (JFET), a wideband-gap (WBG) device, or an ultra-wideband-gap (UWBG) device.

[0007] In other features, the solid state fuse device includes a current sensor connected between the traction battery and the switch, wherein the current sensor is configured to output an overcurrent signal indicative of an overcurrent measured by the current sensor.

[0008] In other features, the solid state fuse device includes a latch connected to an output of the current sensor, wherein the latch is configured to output a latch state signal indicative of a state maintained by the latch.

[0009] In other features, the latch is configured to transition from a first state to a second state when the overcurrent signal exceeds a predetermined overcurrent threshold, and to output a latch state signal indicating the second state to disable the gate driver.

[0010] In other features, the latch is configured to transition from the second state to the first state after receiving a reset signal, and output a latch state signal indicating the first state to enable the gate driver.

[0011] In other features, the electrical system includes a delay circuit configured to output the over-current signal after an adjustable delay period.

[0012] In other features, the gate driver is configured to measure a voltage drop across the switch.

[0013] In other features, a switch is connected between the traction battery and the power inverter module.

[0014] According to several aspects of the present disclosure, a solid-state fuse device includes a switch and a gate driver, the gate driver being connected to the switch and configured to transition the switch from a closed state to an open state when at least one of an overcurrent measurement exceeds a predetermined overcurrent threshold or a voltage drop across the switch exceeds a predetermined saturation voltage threshold. The solid-state fuse device also includes a current sensor connected between a traction battery and the switch, wherein the current sensor is configured to output an overcurrent signal to the gate driver indicating an overcurrent measured by the current sensor.

[0015] In other features, the switch comprises a voltage controlled switching device.

[0016] In other features, the voltage-controlled switching device includes at least one of a silicon insulated gate bipolar transistor (IGBT), a metal-oxide semiconductor field effect transistor (MOSFET), a silicon super junction MOSFET, a gallium nitride (GaN) field effect transistor (FET), a SiC junction field effect transistor (JFET), a wide bandgap (WBG) device, or an ultra-wide bandgap device (UWBG).

[0017] In other features, the solid state fuse device includes a latch connected to an output of the current sensor, wherein the latch is configured to output a latch state signal indicative of a state maintained by the latch.

[0018] In other features, the latch is configured to transition from a first state to a second state when the overcurrent signal exceeds a predetermined overcurrent threshold, and to output a latch state signal indicating the second state to disable the gate driver.

[0019] In other features, the latch is configured to transition from the second state to the first state after receiving a reset signal, and output a latch state signal indicating the first state to enable the gate driver.

[0020] In other features, the gate driver is configured to measure a voltage drop across the switch.

[0021] In other features, a switch is connected between the traction battery and the power inverter module.

[0022] According to several aspects of the present disclosure, a solid-state fuse device includes a switch and a gate driver, the gate driver being connected to the switch and configured to transition the switch from a closed state to an open state when at least one of an overcurrent measurement exceeds a predetermined overcurrent threshold or a voltage drop across the switch exceeds a predetermined saturation voltage threshold. The solid-state fuse device also includes: a current sensor connected between a traction battery and the switch, wherein the current sensor is configured to output an overcurrent signal to the gate driver indicating an overcurrent measured by the current sensor; and a latch connected to an output terminal of the current sensor, wherein the latch is configured to output a latch state signal indicating a state maintained by the latch.

[0023] In other features, the latch is configured to transition from a first state to a second state when the overcurrent signal exceeds a predetermined overcurrent threshold, and to output a latch state signal indicating the second state to disable the gate driver.

[0024] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 is a schematic diagram of an example battery electric vehicle according to an example implementation;

[0027] Figure 2 is a circuit diagram of an electrical system of an electric vehicle according to an example embodiment; and

[0028] Figure 3 is a diagram illustrating a solid state fuse device of an electrical system according to an example embodiment. DETAILED DESCRIPTION

[0029] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0030] A fuse is a circuit element that can transition from a closed state to an open state (e.g., an open circuit) to prevent current flow when the current exceeds a certain threshold. A resettable fuse can transition between a closed state and an open state depending on the current in the electrical system. For example, a resettable fuse can transition to an open state to mitigate an overcurrent fault within an electrical system.

[0031] A solid-state fuse device is disclosed that may include a plurality of control circuits. For example, the solid-state fuse device may include a switch and a gate driver connected to the switch and configured to transition the switch from a closed state to an open state when an overcurrent measurement exceeds a predetermined overcurrent threshold or a voltage drop across the switch exceeds at least one of a predetermined saturation voltage threshold. As discussed herein, the overcurrent may be measured via a current sensor, and the voltage drop across the switch terminals may be measured. Thus, the solid-state fuse device may distinguish between a short circuit fault and an overcurrent event.

[0032] Figure 1 A schematic diagram of an example of a plug-in hybrid-electric vehicle (PHEV) is depicted. The vehicle 12 may include one or more electric machines 14 that are mechanically connected to a hybrid transmission 16. The electric machine 14 is capable of operating as a motor and / or a generator. In addition, the hybrid transmission 16 may be mechanically connected to an engine 18. The hybrid transmission 16 may also be mechanically connected to a drive shaft 20 that is mechanically connected to wheels 22. The electric machine 14 may provide propulsion and deceleration capabilities when the engine 18 is turned on or off. The electric machine 14 may also be used as a generator and may provide fuel economy benefits by recovering energy that would normally be lost as heat in a friction braking system.

[0033] The traction battery 24 (e.g., a battery pack) stores and provides energy that can be used by the motor 14 or other components of the vehicle 12. The traction battery 24 generally provides a high-voltage DC output from one or more battery cell arrays (sometimes referred to as battery cell stacks) within the traction battery 24. The high-voltage DC output can also be converted to a low-voltage DC output for applications such as vehicle stop / start. The battery cell array can include one or more battery cells. The traction battery 24 can be electrically connected to one or more power inverter modules 26 through one or more contactors. The one or more contactors isolate the traction battery 24 from other components when open and connect the traction battery 24 to other components when closed. The power inverter module 26 is also electrically connected to the motor 14 and provides the ability to transfer electrical energy bidirectionally between the traction battery 24 and the motor 14. For example, a typical traction battery 24 can provide a DC voltage, while the motor 14 may require a three-phase AC voltage to operate. The power inverter module 26 can convert the DC voltage into a three-phase AC voltage according to the requirements of the motor 14. In the regenerative mode, the power inverter module 26 can convert the three-phase AC voltage from the motor 14 as a generator into the DC voltage required by the traction battery 24. The description herein may be applicable to pure electric vehicles or other hybrid vehicles. For pure electric vehicles, the hybrid transmission 16 may be a gearbox connected to the electric machine 14, and the engine 18 may not be present.

[0034] In addition to providing energy for propulsion, the traction battery 24 can provide energy for other electrical systems of the vehicle. A typical vehicle electrical system may include a DC / DC converter module 28 that converts the high voltage DC output of the traction battery 24 into a low voltage DC power source that is compatible with other loads of the vehicle. Other high voltage loads (such as compressors and electric heaters) can be connected directly to the high voltage without using the DC / DC converter module 28. In a typical vehicle, the low voltage system is electrically connected to an auxiliary battery 30 (e.g., a 12V battery).

[0035] A battery electrical control module (BECM) 33 may be in communication with the traction battery 24. The BECM 33 may serve as a controller for the traction battery 24 and may also include an electronic monitoring system that manages the temperature and state of charge of each of the battery cells. The traction battery 24 may have a temperature sensor 31, such as a thermistor or other thermometer. The temperature sensor 31 may communicate with the BECM 33 to provide temperature data regarding the traction battery 24. The temperature sensor 31 may also be located on or near a battery cell within the traction battery 24. It is also contemplated that more than one temperature sensor 31 may be used to monitor the temperature of a battery cell.

[0036] For example, the vehicle 12 may be an electric vehicle (such as a PHEV, FHEV, MHEV, or BEV) in which the traction battery 24 may be recharged by an external power source 36. The external power source 36 may be a connection to an electrical outlet. The external power source 36 may be electrically connected to an electric vehicle supply equipment (EVSE) 38. The EVSE 38 may provide circuitry and control to regulate and manage the transfer of electrical energy between the power source 36 and the vehicle 12. The external power source 36 may provide DC or AC power to the EVSE 38. The EVSE 38 may have a charging connector 40 for plugging into a charging port 34 of the vehicle 12. The charging port 34 may be any type of port configured to transfer power from the EVSE 38 to the vehicle 12. The charging port 34 may be electrically connected to a charger or an onboard power conversion module 32. The power conversion module 32 may regulate the power supplied from the EVSE 38 to provide a suitable voltage level and current level to the traction battery 24. The power conversion module 32 may interface with the EVSE 38 to coordinate power delivery to the vehicle 12. The EVSE connector 40 may have pins that mate with corresponding recesses of the charging port 34 .

[0037] The various components discussed may have one or more associated controllers to control and monitor the operation of the components. The controllers may communicate via a serial bus (eg, a Controller Area Network (CAN)) or via discrete conductors.

[0038] A battery cell, such as a prismatic battery, may include an electrochemical cell that converts stored chemical energy into electrical energy. A prismatic battery may include a housing, a positive electrode (cathode), and a negative electrode (anode). An electrolyte may allow ions to move between the anode and cathode during discharge and then back during recharge. The terminals may allow current to flow out of the battery for use by the vehicle. When positioned in an array with multiple battery cells, the terminals of each battery cell may be aligned with opposite terminals (positive and negative) adjacent to each other, and a bus may assist in facilitating series connection between multiple battery cells. The battery cells may also be arranged in parallel so that similar terminals (positive and positive or negative and negative) are adjacent to each other. For example, two battery cells may be arranged with the positive terminals adjacent to each other, and the next two battery cells may be arranged with the negative terminals adjacent to each other. In this example, the bus may contact the terminals of all four batteries. The traction battery 24 may be heated and / or cooled using a liquid thermal management system, an air thermal management system, or other methods known in the art.

[0039] Figure 2 An example electrical system 100 is illustrated that includes a traction battery 24, an electric power inverter module 26, and an electric machine 14. Figure 2 , the electric machine 14 is shown as a traction motor 102 .

[0040] The power inverter module 26 may include a group 104 of semiconductor switches S1 to S6 (also referred to herein as "inverter switches") that, during vehicle operation (e.g., during motor operation mode), coordinately convert direct current (DC) power from the traction battery 24 into alternating current (AC) power for powering the traction motor 102 via high-frequency switching. Each semiconductor switch S1 to S6 may be implemented as a voltage-controlled switch device in the form of a silicon insulated gate bipolar transistor (IGBT), a silicon carbide (SiC) metal-oxide semiconductor field effect transistor (MOSFET), a silicon (Si) superjunction MOSFET, a gallium nitride (GaN) field effect transistor (FET), a SiC junction field effect transistor (JFET), other wide bandgap (WBG) or ultra-wide bandgap semiconductor power switch devices (UWBG), or other suitable switches with corresponding gates to apply gate signals to change the on / off state. Each phase of the three-phase traction motor 102 typically has at least one pair of semiconductor switches. Each pair of switches, such as switches S1 and S2 (Phase A), switches S3 and S4 (Phase B), and switches S5 and S6 (Phase C), may be referred to as a phase leg of the power inverter module 26. For example, in an exemplary embodiment, the power inverter module 26 may include at least three (3) phase legs. Each phase leg of the power inverter module 26 is connected to a corresponding machine phase terminal of the traction motor 102. Figure 2 As shown, the DC link capacitor C may be connected between the positive connector 106 and the negative connector 108 .

[0041] The electrical system 100 also includes a solid-state fuse device 110. As shown, the solid-state fuse device 110 can be connected between the traction battery 24 and the power inverter module 26. Reference numerals L and R represent an inductive circuit element and a resistive circuit element, respectively, which may include an electrical connection between the solid-state fuse device 110 and the power inverter module 26. In an example embodiment, the electrical connection may include any suitable electrical connection, such as an electrical connector (e.g., a cable).

[0042] The solid-state fuse device 110 may include a switch 112, such as a voltage-controlled switch device. Examples of voltage-controlled switch devices are described above with reference to the power inverter module 26. The switch 112 includes a first terminal 114, a second terminal 116, and a gate terminal 118. The first terminal 114 and the second terminal 116 may be arranged such that the switch 112 is connected in series along the positive connector 106 to control the flow of current between the traction battery 24 and the power inverter module 26.

[0043] The operation of the solid-state fuse device 110 can be controlled by measuring two different current values. As described in more detail herein, the solid-state fuse device 110 can measure overcurrent and can measure short-circuit fault current through the electrical system 100. During operation, the solid-state fuse device 110 can allow current to flow through the electrical system 100. However, in the event that the solid-state fuse device 110 detects that at least one of the overcurrent or the short-circuit fault current exceeds a predetermined current threshold, the solid-state fuse device 110 can prevent current from flowing until a reset signal is received.

[0044] The solid-state fuse device 110 may also include a current sensor 120. The current sensor 120 may be connected along the positive connector 106 and measure the amount of current passing through the positive connector 106. The solid-state fuse device 110 also includes a gate driver 128. The gate driver 128 may receive an input from the output 130 of the latch 136 and an input from the terminals 124, 126 connected in parallel with the switch 112. As described in more detail below, the latch 136 may provide an overcurrent signal indicating an overcurrent signal measured by the current sensor 120. The gate driver 128 may measure a voltage drop across the switch 112 via the terminals 124, 126, the voltage drop across the switch 112 corresponding to a short-circuit fault current, as described in more detail below. As shown in the figure, the first terminal 124 may be connected to the first terminal 114 of the switch 112, and the second terminal 126 may be connected to the second terminal 116.

[0045] The gate driver 128 can generate a control signal that controls the operation of the switch 112 based on the received input, as discussed in more detail below. For example, the gate driver 128 can include a MOSFET driver that converts the received input signal into a corresponding voltage signal that controls the operation of the switch 112. The switch 122 can transition between an open state (e.g., an off state) and a closed state (on state). In the open state, the switch 122 blocks the flow of current, and in the closed state, the switch 122 allows the flow of current. The gate driver 128 can provide a control signal to the gate terminal 118 of the switch 122 via the output terminal 134.

[0046] Current sensor 120 may include any suitable sensor capable of directly measuring current and generating a signal indicative of the measured overcurrent. Current sensor 120 may be configured to generate an overcurrent signal based on a predetermined current threshold provided to latch 136, such as a predetermined value above a maximum operating current.

[0047] In an example embodiment, the latch 136 may include a trigger, such as a set-reset trigger. The latch 136 may receive an overcurrent signal as an input from the output 140 of the current sensor 120. The latch 136 may also receive a reset signal at the input 142, which causes the state stored by the latch 136 to transition. For example, initially, the latch 136 may store a first state in which a latch state signal indicating the stored state is provided to the gate driver 128 via the output 130 to enable the operation of the gate driver 128. The latch 136 may be configured to transition the state based on the received overcurrent signal. For example, when the overcurrent signal exceeds a predetermined overcurrent threshold, the latch 136 may transition from the first state to the second state. If the latch 136 transitions to the second state, the latch state signal transitions and the operation of the gate driver 128 may be disabled, for example, causing the switch 112 to transition from a closed state to an open state. Latch 136 may provide a latch state signal indicating the second state until a reset signal is received, causing latch 136 to transition from the second state to the first state. The latch state signal may also transition to enable operation of gate driver 128, thereby causing switch 112 to transition from an open state to a closed state.

[0048] refer to Figure 3 , the electrical system 100 may include a delay circuit 202 that may output an overcurrent signal after a delay period. In an example embodiment, the delay circuit 202 outputs the overcurrent signal to the latch 136 after the delay period. In various embodiments, the delay period may range from about five (5) microseconds to about five hundred (500) milliseconds. By using the delay circuit 202, a selected inrush current distribution is allowed. For example, the allowed inrush current can be distinguished from an overcurrent event and a short circuit fault. In an example embodiment, the delay circuit 202 may include a controllable delay circuit 202 so that the delay period is adjustable, for example, it can be set. Although the delay circuit 202 is illustrated as being included in the current sensor 120, it should be understood that the delay circuit 202 may be separate and / or different from the current sensor 120. For example, the delay circuit 202 may be connected in series with the current sensor 120.

[0049] As described above, the gate driver 128 can measure the voltage drop across the switch 112 via the terminals 124, 126. The measured voltage drop can correspond to the amount of current flowing through the switch 112. In an example embodiment, the gate driver 128 can include a desaturation fault detection circuit 204 (e.g., a DESAT detection circuit) that can cause the switch 112 to transition from a closed state to an open state when the voltage drop exceeds a predetermined saturation voltage threshold (e.g., a DESAT voltage). The electrical system 100 may be experiencing excessive current (such as a load short circuit current), which may cause damage to components of the electrical system 100 when the voltage drop exceeds the DESAT voltage. As shown, the gate driver 128 can receive a reset signal via the input terminal 142, which can cause the gate driver 128 and / or the desaturation fault detection circuit 204 to output a control signal that causes the switch 112 to transition from an open state to a closed state.

[0050] It should be appreciated that the reset signal may be provided by various components of the vehicle 12. For example, in an example embodiment, the reset signal may be provided by a battery electrical control module (BECM) 33. However, it should be appreciated that the reset signal may be provided by any suitable vehicle 12 module, such as an electronic control module.

[0051] It should be understood that the one or more thresholds corresponding to the current sensor 120 may be different than the one or more thresholds corresponding to the voltage drop across the switch 112. For example, the one or more thresholds corresponding to the voltage drop relate to current levels that last for less than or equal to two (2) microseconds (μs), and the one or more thresholds corresponding to the current sensor relate to current levels that are greater than a predetermined overcurrent threshold and last longer than a delay period (e.g., an adjustable delay period).

[0052] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as departing from the spirit and scope of the present disclosure.

Claims

1. A solid-state fuse device, comprising: a switch having a first switch terminal, a second switch terminal, and a switch gate terminal; as well as a current sensor having a first current measurement terminal connected to a traction battery, a second current measurement terminal connected to the switch, and an overcurrent signal output terminal, wherein the current sensor is configured to output an overcurrent signal to the overcurrent signal output terminal in response to determining that the current sensor has measured an overcurrent for at least an adjustable delay time period; a latch having a first latch input terminal configured to receive a reset signal, a second latch input terminal connected to the overcurrent signal output terminal of the current sensor, and a latch output terminal, wherein the latch is configured to output a latch state signal indicating a state maintained by the latch to the latch output terminal, and wherein the latch is configured to transition from a first state to a second state when the overcurrent signal exceeds a predetermined overcurrent threshold, and output the latch state signal indicating the second state to the latch output terminal; as well as a gate driver having a first gate driver input configured to receive the reset signal, a second gate driver input connected to the latch output, a third gate driver input connected to the first switch terminal, a fourth gate driver input connected to the second switch terminal, and a gate driver output connected to the switch gate terminal, the gate driver being connected to the switch, wherein the gate driver is configured to: transitioning the switch from a closed state to an open state when an overcurrent measurement exceeds the predetermined overcurrent threshold for the at least adjustable delay period, wherein the overcurrent measurement is determined based at least in part on the latch state signal received at the second gate driver input; as well as transitioning the switch from the closed state to the open state when a voltage drop across the switch exceeds a predetermined saturation voltage threshold, wherein the voltage drop across the switch is determined at least in part based on a voltage difference between the third gate driver input and the fourth gate driver input; as well as When the reset signal is received at the first gate driver input, the switch is transitioned from the open state to the closed state.

2. The solid state fuse device of claim 1, wherein the switch comprises a voltage controlled switching device.

3. The solid-state fuse device of claim 2, wherein the voltage-controlled switch device comprises at least one of a silicon insulated gate bipolar transistor (IGBT), a metal-oxide semiconductor field effect transistor (MOSFET), a silicon super junction MOSFET, a gallium nitride (GaN) field effect transistor (FET), a SiC junction field effect transistor (JFET), a wide bandgap (WBG) device, or an ultra-wide bandgap device (UWBG). 4 . The solid-state fuse device of claim 3 , wherein the latch is configured to transition from the second state to the first state after receiving the reset signal, and output the latch state signal indicating the first state to enable the gate driver. 5 . The solid-state fuse device of claim 3 , further comprising a delay circuit configured to output the overcurrent signal after the adjustable delay period.

6. The solid state fuse device of claim 1, wherein the switch is connected between the traction battery and a power inverter module.

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