Power circuit for charging an electric vehicle and having a DC / DC converter for supplying power to auxiliary devices

Abstract

A power circuit (100) is disclosed, comprising a charging input (102) for receiving electrical energy at a first voltage or a second voltage for charging a traction battery (106) of a vehicle, a battery connection terminal (104) for electrically connecting to the traction battery to supply electrical energy from the charging input for charging the traction battery at the first voltage or the second voltage and to receive electrical energy from the traction battery for powering one or more traction motors (108) of the vehicle at the second voltage, and a DCDC converter (112) coupled to the charging input and to an output for connecting the DCDC converter to an electrical bus for providing electrical power at an output voltage to one or more electrical units, the DCDC converter being configured to receive electrical energy from the charging input and to provide electrical energy at the output voltage while charging the traction battery at the first voltage.

Description

Technical Field

[0001] This disclosure relates to electrical circuits for vehicles. Aspects include electrical circuits, battery modules, control systems, systems, vehicles, methods, and computer software. Background Technology

[0002] Electric vehicles and hybrid electric vehicles include a traction motor and a traction battery that supplies power to the traction motor. Some traction batteries can be recharged using electrical energy from outside the vehicle, such as from the power grid.

[0003] Until recently, battery electric (BEV) vehicles operated at a nominal voltage of 400V. There has been a persistent demand to increase the charging speed of BEVs, which requires higher charging power. With increased charging power, the charging current increases. Associated losses (such as heat loss) also increase because the heating of electrical components, such as cables, depends on the current (power equals the square of the current multiplied by the resistance, P = I). 2 Doubling the operating voltage would halve the current delivered for the same power (P = IV). However, existing vehicle components / electrical systems operate at 400V, and it is undesirable to use entirely new and different components / electrical systems to handle different voltages and maintain power output. Furthermore, the operating voltage needs to be changed for example, during battery charging rather than while driving the vehicle (which is likely the primary use due to the time spent operating the vehicle's electrical system).

[0004] Many BEV charging facilities operate at 400V. However, it would be desirable to be able to use 800V charging, as charging can be done much faster than at 400V. However, if the vehicle's electrical components / circuit system are designed to operate at 800V, then it would be impossible to use most (400V) charging stations. This presents a significant challenge if the battery packs used in high-voltage (e.g., exceeding approximately 350V) systems for BEVs and vehicles are designed to operate at 400V, posing a considerable challenge to charging such systems at 800V. Conversely, a similar problem arises if the system is designed to operate at 800V, as charging at 400V would be impossible.

[0005] By using a combination of configurable control devices within the battery pack of a BEV, the operating voltage of the battery pack can be adjusted between, for example, 400V and 800V. This can be achieved, for example, by placing two 400V battery packs in parallel or series and switching between these configurations using a switching connection device.

[0006] Problems may arise when using vehicle auxiliary units, such as those managing the battery pack's thermal conditions (e.g., cooling and heating systems), during battery pack charging at 800V. These auxiliary units may require a 400V power supply instead of the 800V power used for charging the battery pack. Furthermore, it is desirable for the vehicle's electrical circuitry and components to accommodate different configuration options within the HV architecture.

[0007] Furthermore, the DC-DC and OBC (On-Board Charger) circuit systems in electric vehicles typically have fixed voltage outputs. However, in electric vehicle design, multiple voltage outputs can exist depending on the systems within the vehicle. Examples include drive inverters operating at 400V and advanced driver assistance systems (ADAS) operating at 12V / 48V, while the HV battery can be charged at 800V. Therefore, it is desirable for vehicle circuit systems and components to provide different output voltages, such as 400V or 12V, especially when the vehicle's battery pack is charged again at a different voltage, such as 800V. Using multiple DC-DC converters within the vehicle is undesirable, as this increases the complexity and cost of the vehicle's electrical architecture.

[0008] The examples disclosed herein are intended to address one or more of the drawbacks associated with the prior art. Summary of the Invention

[0009] A possible solution to the problems mentioned above is a system that can (e.g., at a high voltage of, for example, 400V and / or a low voltage of, for example, 12V) provide a stable output to the vehicle's auxiliary circuitry, regardless of the charging voltage (e.g., 400V or 800V). Such a system could, for example, support both LV (low voltage) and HV (high voltage) systems simultaneously.

[0010] This can provide flexible and reconfigurable electrical systems that can be initially designed and delivered, but then used in various configurations for different applications and vehicles. There may be a desire to improve the flexibility of circuit systems to provide different output voltages, especially in the automotive industry where a common design for circuit systems is desired. This can allow for lower manufacturing and design costs and labor, while still providing flexibility for electrical configurations tailored to different vehicle applications, i.e., for different customers and markets. Such a system, for example, could support both 800V and 400V traction systems.

[0011] The various aspects disclosed herein provide for power circuits, battery components, control systems, systems, vehicles, methods, and computer software.

[0012] According to one aspect of the present invention, an electrical circuit for a vehicle is provided, comprising: a charging input terminal for receiving electrical energy at a voltage equal to a first voltage or a second voltage for charging a traction battery of the vehicle; a battery connection terminal for electrically connecting to the traction battery to supply electrical energy from the charging input terminal for charging the traction battery at the first voltage or the second voltage, and for receiving electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage; and a DC-DC converter coupled to the charging input terminal and an output terminal, the output terminal being used to electrically connect the DC-DC converter to the vehicle's electrical bus for providing power to one or more electrical units of the vehicle at an output voltage. The DC-DC converter is configured to receive electrical energy from the charging input terminal and provide electrical energy to the output terminal at an output voltage while simultaneously charging the traction battery at the first voltage.

[0013] In some examples, the first voltage can be higher than the second voltage. The first and second voltages can be non-overlapping ranges. The output voltage can be lower than the first and second voltages.

[0014] The first voltage may include a nominal voltage in the range of 600V to 1000V; the second voltage may include a nominal voltage in the range of 300V to 500V; and the output voltage may include a nominal voltage in the range of 12V to 48V.

[0015] In some examples, the output voltage can be a second voltage.

[0016] For example, the charging input can provide a higher charging voltage, such as 800V (or, if available, a different voltage, such as 400V), to the traction battery, while simultaneously providing a lower voltage, such as 400V or 12V, to the output / electrical bus for use with auxiliary units such as heaters or coolers operating at 400V and / or for use with auxiliary units such as onboard equipment charging points at 12V, regardless of whether the battery is being charged at 400V or 800V. Therefore, auxiliary units can operate at their preferred voltages while charging the battery at an available voltage, which may be higher than the voltage required by the auxiliary units. This allows for maintaining battery operating conditions to ensure operational efficiency and / or protection against battery degradation.

[0017] A DC-DC converter may include a first DC-DC converter module and a second DC-DC converter module. The first DC-DC converter module may be coupled to a charging input and a first output, the first output being used to electrically connect the first DC-DC converter module to a first electrical bus of the vehicle to provide power to one or more first electrical units of the vehicle at a first output voltage. The second DC-DC converter module may be coupled to the charging input and the second output, the second output being used to electrically connect the second DC-DC converter module to a second electrical bus of the vehicle to provide power to one or more second electrical units of the vehicle at a second output voltage. The DC-DC converter may be configured to: receive electrical energy from the charging input; provide electrical energy to the first output at the first output voltage while charging the traction battery at a first voltage or a second voltage; and provide electrical energy to the second output at the second output voltage.

[0018] The power circuit may include an AC charging input. The DC-DC converter can be configured to receive electrical energy from the AC charging input and to supply electrical energy to the battery connection terminals at a first voltage for charging the traction battery.

[0019] This output can be used to electrically connect the DC-DC converter to the vehicle's electrical bus to provide power to one or more auxiliary electrical units of the vehicle at the output voltage while charging the traction battery via AC charging.

[0020] The electrical unit may include one or more of the following: a heater; a cooler; an air conditioning compressor; a power-assisted steering system; an active roll control pump; a suspension compressor; and a heated windshield. The electrical unit may also be any other auxiliary device that can be converted from operating at 12V to operating at 400V. This may include a power inverter for providing alternating current (AC) to power household appliances.

[0021] The power circuit may include an on-board charger coupled to the DC-DC converter, the on-board charger being configured to receive AC current and supply DC current to the DC-DC converter.

[0022] In some examples, the on-board charger can operate independently, enabling the provision of a power circuit for the vehicle. The on-board charger includes: an AC charging input for receiving electrical energy to charge the vehicle's traction battery; a battery connection terminal for electrically connecting to the traction battery to supply electrical energy from the AC charging input for charging the traction battery; and an ACDC converter coupled to the AC charging input and the battery connection terminal. The ACDC converter can be configured to receive electrical energy from the AC charging input and supply electrical energy to the battery connection terminal at a first voltage within a first voltage range or a second voltage within a second voltage range, wherein the first and second voltage ranges are non-overlapping voltage ranges. The output of the OBC can supply an HV bus connected to the battery connection terminal. Therefore, in some examples, the external battery pack 106 can be configured to receive power while the DC-DC converter of the power circuit is operating.

[0023] On the other hand, a battery assembly is provided, including a traction battery and a power circuit, wherein the traction battery includes a battery input / output terminal, and wherein the battery input / output terminal is electrically connected to a battery connection terminal.

[0024] The traction battery may include a first plurality of battery cells, a second plurality of battery cells, and a battery control circuit, which selectively interconnects the first plurality of battery cells and the second plurality of battery cells in series to provide a first battery voltage at the battery output in a first operating mode, and selectively interconnects the first plurality of battery cells and the second plurality of battery cells in parallel to provide a second battery voltage at the battery output in a second operating mode.

[0025] On the other hand, a control system for controlling the electrical circuit of a vehicle is provided, the control system including one or more controllers, the electrical circuit including: a charging input terminal for receiving electrical energy at a voltage equal to a first voltage or a second voltage for charging a traction battery of the vehicle; and a battery connection terminal for electrically connecting to the traction battery to supply electrical energy from the charging input terminal for charging the traction battery at the first voltage or the second voltage, and for receiving electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage; and a DC-DC converter coupled to the charging input terminal and an output terminal for electrically connecting the DC-DC converter to the vehicle's electrical bus for providing power to one or more electrical units of the vehicle at an output voltage; wherein the control system is configured to control the DC-DC converter in the electrical circuit to:

[0026] Receive electrical energy from the charging input terminal, and

[0027] While charging the traction battery with the first voltage, it provides electrical energy to the output terminal with the output voltage.

[0028] One or more controllers may collectively include: at least one electronic processor having electrical inputs for receiving information from one or more sensors and / or one or more external controllers; and at least one electronic memory device electrically coupled to the at least one electronic processor and having instructions stored therein; and the at least one electronic processor may be configured to access the at least one memory device and execute instructions thereon to cause the control system to control the DC-DC converter based on the information.

[0029] The first voltage can be higher than the second voltage. The first and second voltages can be non-overlapping ranges. The output voltage can be lower than the first and second voltages.

[0030] The first voltage may include a nominal voltage in the range of 600V to 1000V. The second voltage may include a nominal voltage in the range of 300V to 500V. The output voltage may include a nominal voltage in the range of 12V to 48V. The output voltage may be the second voltage.

[0031] The power circuit may include an AC charging input. The control system may be configured to control a DC-DC converter to receive electrical energy from the AC charging input (e.g., via an AC-DC conversion element) and to supply electrical energy to the battery connection terminals at a first voltage for charging the traction battery.

[0032] On the other hand, a system is provided that includes a battery assembly as disclosed herein and a control system as disclosed herein.

[0033] In another aspect, a vehicle is provided, including an electrical circuit as disclosed herein, a battery assembly as disclosed herein, a control system as disclosed herein, or a system as disclosed herein.

[0034] The vehicle may include an electrical bus. The electrical bus may include a high-voltage (HV) auxiliary power bus, which is configured to provide power to one or more auxiliary units of the vehicle at a second voltage.

[0035] On the other hand, a method is provided for controlling an electrical circuit for a vehicle, the electrical circuit comprising: a charging input for receiving electrical energy at a voltage equal to a first voltage or a second voltage for charging a traction battery of the vehicle; and a battery connection terminal for electrically connecting to the traction battery to supply electrical energy from the charging input for charging the traction battery at the first voltage or the second voltage, and for receiving electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage; and a DC-DC converter coupled to the charging input and an output for electrically connecting the DC-DC converter to the vehicle's electrical bus to provide power to one or more electrical units of the vehicle at an output voltage. The method includes controlling the DC-DC converter to: receive electrical energy from the charging input; and simultaneously charge the traction battery at the first voltage while supplying electrical energy to the output at the output voltage.

[0036] On the other hand, computer software is provided that, when executed, is configured to perform any of the methods disclosed herein. Optionally, the computer software is stored on a computer-readable medium. Optionally, the computer software is tangibly stored on a computer-readable medium.

[0037] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set forth in the preceding paragraphs, in the claims, and / or in the following description and drawings, and in particular their various features, may be employed independently or in any combination. That is, all embodiments and / or features of any embodiment may be combined in any manner and / or combination, unless such features are incompatible. The applicant reserves the right to amend any initially filed claim or accordingly file any new claim, including the right to modify any initially filed claim to subordinate to and / or incorporate any feature of any other claim, even if not initially claimed in this manner. Attached Figure Description

[0038] One or more embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0039] Figure 1 An example of an electrical circuit disclosed herein is shown;

[0040] Figure 2 A power circuit with an AC input is shown according to an example disclosed herein;

[0041] Figure 3 A power circuit with an on-board charger, according to an example disclosed herein, is shown;

[0042] Figure 4A power circuit connected to a traction battery, according to an example disclosed herein, is shown;

[0043] Figure 5 A power circuit connected to a traction battery, according to an example disclosed herein, is shown;

[0044] Figure 6 A control system based on an example disclosed herein is shown;

[0045] Figure 7 A system based on an example disclosed herein is shown;

[0046] Figure 8 The vehicle shown is an example according to the disclosure herein; and

[0047] Figure 9 The method is shown according to the example disclosed in this article. Detailed Implementation

[0048] The examples disclosed herein can provide flexible voltage outputs for use in electric vehicles. Some examples can support both 800V and 400V traction systems. It may be desirable to charge the vehicle's battery at a voltage different from the output voltage supplied to the vehicle's electrical system. For example, it may be desirable to charge the vehicle's battery with either a 400V or 800V power supply while, for instance, the vehicle's electrical system is supplied with 400V. For example, it may be desirable to operate the vehicle's heater or cooler unit during battery charging; battery charging may be available at 800V, but the heater / cooler may require a different voltage, such as 400V, to operate.

[0049] Some examples can support both LV (low voltage) and HV (high voltage) systems simultaneously. The ability to accept, for example, essentially 800V (e.g., between 650V and 850V) or essentially 400V (e.g., between 270V and 470V) at the same input allows for flexible systems capable of operating with different voltage requirements. It is desirable to allow bidirectional operation (i.e., allowing the vehicle's battery to be charged, and allowing the charge stored in the vehicle's battery to be used to power the vehicle).

[0050] The examples discussed in this article provide circuits for the automotive industry that can be advantageous in allowing the flexible use of existing systems, i.e., accepting different possible voltages at the input for charging and providing different possible voltages for use during charging, without requiring entirely new and different circuit systems designed for specific fixed voltage inputs and / or outputs.

[0051] Figure 1An electrical circuit 100 for a vehicle is shown. The circuit 100 includes a charging input 102 for receiving electrical energy. Electrical energy can be received at a voltage equal to a first voltage V1 or a second voltage V2 for charging the vehicle's traction battery. For example, the charging input 102 can receive energy at a voltage such as V1 = 800V or between 650V and 850V, or at a voltage such as V2 = 400V or between 270V and 470V, depending on the voltage used at the charging station supplying the electrical energy.

[0052] Circuit 100 includes a battery connection terminal 104 for electrical connection to the vehicle's traction battery 106. This terminal supplies electrical energy from a charging input terminal 102 to charge the traction battery 106 at a first voltage V1 or a second voltage V2, and receives electrical energy from the traction battery 106 to power one or more traction motors 108 of the vehicle at the second voltage V2. For example, electrical energy from the charging input terminal 102 can be supplied at V1 = 800V or V2 = 400V to charge the traction battery 106, and the traction motors 108 can be powered by the traction battery 106 at V2 = 400V.

[0053] Circuit 100 includes a DC-DC converter 112 coupled to a charging input 102 and an output 110. The output 110 is used to electrically connect the DC-DC converter 112 to the vehicle's electrical bus for supplying power to one or more electrical units of the vehicle at an output voltage. The DC-DC converter 112 is configured to receive electrical energy from the charging input 102 and supply electrical energy to the output 110 at its output voltage while charging the traction battery 106 at a first voltage that may differ from the output voltage; that is, supplying electrical energy at the output 110 during the charging of the traction battery 106 (i.e., during the period when electrical energy is input to circuit 100 to charge the connected battery 106).

[0054] For example, the DC-DC converter 112 can receive electrical energy from the charging input 102 and simultaneously charge the traction battery 106 at a first voltage of, for example, 800V, to the output 110 at an output voltage of, for example, 400V or, for example, 12V. Therefore, even if vehicle auxiliary units connected to the battery 106 via the electrical bus through circuit 100 require different operating voltages, such as 400V or 12V, the higher voltage at, for example, 800V can be utilized, and these auxiliary units can be operated while the battery is being charged at, for example, a voltage different from the operating voltage of the auxiliary units. This could be useful, for example, in a situation where a heater is used to warm the battery at, for example, 400V while the battery is being charged at, for example, 800V.

[0055] Therefore, in some examples, the first voltage (e.g., 800V) can be higher than the second voltage (e.g., 400V). In some examples, the first and second voltages can be non-overlapping ranges (e.g., the first voltage can be between 650V and 850V, and the second voltage can be between 270V and 470V). In some examples, the output voltage (e.g., 12V, or a low voltage range of, for example, 5V to 48V) can be lower than the first voltage (e.g., 800V, or 650V to 850V) and the second voltage (e.g., 400V, or 270V to 470V).

[0056] Therefore, in some examples, for instance, the first voltage may include a nominal voltage in the range of 600V to 1000V; the second voltage may include a nominal voltage in the range of 300V to 500V; and / or the output voltage may include a nominal voltage in the range of 12V to 48V. In some examples, a unit operating at an output voltage of 400V may operate at a power of 15kW. In some examples, a unit operating at a low output voltage of 12V may operate at a power of 4kW.

[0057] In some examples, the output voltage may be a second voltage. For example, the battery may be charged at a first voltage of 800V or 400V, the second voltage used to power the traction motor may be 400V, and the output voltage used to power, for example, a cooling unit may also be 400V. In some examples, the output voltage may not be a second voltage. For example, the battery may be charged at a first voltage of 800V or 400V, the second voltage used to power the traction motor may be 400V, and the output voltage used to power, for example, a personal device charging point may be a low voltage, such as a voltage in the range of 5V to 48V, such as 12V, 24V, 36V, or 48V.

[0058] Electrical units that can be powered by an output voltage (which may or may not be a second voltage used to power a traction motor) include, for example, heaters, coolers, air conditioning compressors, power steering systems, active roll control pumps, suspension compressors, heated windshields, and personal device charging points.

[0059] In this example, charging input terminal 102 forms an external connection, for example, to a charging supply station, and is connected to DC-DC converter 112. Battery connection terminal 104 forms an external connection, for example, to an external battery pack / traction battery 106, and is connected to DC-DC converter 112. There is also a direct connection between charging input terminal 102 and battery connection terminal 104 that does not pass through DC-DC converter 112. There is also a direct connection between battery connection terminal 104 and connections to one or more traction motors 108 that does not pass through DC-DC converter 112. Output terminal 110 forms an external connection, for example, to the vehicle's electrical bus, which in turn supplies power to one or more electrical units of the vehicle. Output terminal 110 is connected to DC-DC converter 112.

[0060] Figure 2 A power circuit 100 with an AC charging input terminal 114 is shown. Further details regarding [the circuit] will not be discussed here. Figure 1 The common characteristics of the circuits. In this example, the DC-DC converter 112 is configured to receive electrical energy from the AC charging input 114 (e.g., via an AC-DC conversion element) and supply electrical energy to the battery connection terminal 104 at a first voltage V1 for charging the traction battery. In such an example, the output terminal 110 is used to electrically connect the DC-DC converter 112 to the vehicle's electrical bus for use at the output voltage V1. out It provides power to one or more auxiliary electrical units of the vehicle while simultaneously charging the traction battery via AC charging. In this example, the AC charging input 114 forms an external connection, for example, for connecting to an AC charging power source, and is also connected to the DC-DC converter 112.

[0061] Figure 3 The power circuit 100 with an on-board charger (OBC) 116 is shown. Details regarding [the circuit] will not be discussed further here. Figure 1 The circuits share common characteristics. The on-board charger 116 is coupled to the DC-DC converter 112. The on-board charger 116 is configured to operate at voltage V at the AC charging input terminal 114. in The AC charging input 114 receives AC current power and supplies DC current power to the DC-DC converter 112. In this example, the AC charging input 114 forms an external connection, for example, to an AC charging supply, and is connected to an OBC 116, which receives AC input power and supplies DC power to the DC-DC converter 112.

[0062] Figure 4 The power circuit 100 connected to the traction battery 106 is shown. Details regarding [the circuit] will not be discussed further here. Figure 1The common features of the circuits. The combination of battery pack / traction battery 106 and circuit 100 can be referred to as "battery assembly" 150. Traction battery 106 includes a battery input / output terminal 118 that is electrically connected to battery connection terminal 104 and allows battery pack 106 to be connected to power circuit 100. The traction battery 106 in this example may include a first plurality of battery cells, a second plurality of battery cells, and battery control circuitry that selectively interconnects the first plurality of battery cells and the second plurality of battery cells in series to provide a first battery voltage at the battery output in a first operating mode, and selectively interconnects the first plurality of battery cells and the second plurality of battery cells in parallel to provide a second battery voltage at the battery output in a second operating mode. For example, the first battery voltage may be 800V and the second battery voltage may be 400V.

[0063] Figure 5 An electrical circuit 100 connected to a traction battery 106 to form a battery assembly 150 of a vehicle, according to an example disclosed herein, is shown. The circuit 100 in this example is labeled as a Battery Electrical Module (BEM). Within the BEM 100, there is a Modular Electrical and Electronic Architecture (MEEA) module 120, which in this example houses a first high-voltage DC-DC converter 112a, a second DC-DC converter 112b, and an OBC 116.

[0064] Circuit 100 includes a charging input 102, labeled "400V / 800V HV DC Charger," for receiving electrical energy. This charging input 102 is connected to DC-DC converters 112a and 112b, to an OBC 116, and via battery connection terminals 104a and 104b to an external battery pack 106. The connection from the charging input 102 to the battery pack 106 is for supplying electrical energy from the charging input 102 to charge the traction battery 106 at a first voltage V1 or a second voltage V2. Electrical energy can be received at either the first voltage V1 (800V in this example) or the second voltage V2 (400V in this example) for charging the traction battery 106.

[0065] Battery connection terminals 104a and 104b electrically connect the traction battery 106 to the BEM 100. Battery connection terminal 104a is electrically connected to DC-DC converters 112a, 112b and OBC 116. The traction battery 106 can be powered via battery connection terminal 104b to power one or more traction motors 108 of the vehicle at a second voltage (in this example, outputs to the HV DC front traction motor and HV DC rear traction motor 108 are shown at 400V). For example, electrical energy from charging input 102 can be used to power the traction battery 106 at 800V or 400V, and the traction motors 108 can be powered by the traction battery 106 at 400V. A DC-DC converter 112a is shown configured to convert an 800V or 400V input to a 400V output (although other high voltage outputs may be provided in different examples). Another DC-DC converter 112b is shown configured to convert an 800V or 400V input to a 12V output (although other low voltage outputs may be provided in different examples). Other examples may include one, three, or more than three DC-DC converters.

[0066] DC-DC converters 112a and 112b are each coupled to the charging input terminal 102 and the output terminals 110a and 110b (in this example, there are two output terminals respectively connected to the corresponding DC-DC converters 112a and 112b). The HV DC-DC converter 112a is connected to the HV output terminal 110a, labeled "400V 15kW Auxiliary Unit" in this example (output terminal 110a itself includes two output channels: a first output channel to the HV DC heater and a second output channel to the HC DC cooler). The LV DC-DC converter 112b is connected to the LV output terminal 110b, labeled "4kW LV DC-DC" in this example. Output terminals 110a and 110b are each connected to the vehicle's electrical bus to provide power to the vehicle's electrical units at the indicated output voltage (in this example, two HV output terminals 110a and one LV output terminal 110b). DC-DC converters 112a and 112b are each configured to receive electrical energy from charging input 102 and to supply electrical energy to outputs 110a and 110b at an output voltage while charging traction battery 106 at a first voltage. In this example, the first output 110a can provide an output at 400V, which may be the same 400V voltage supplied at input 102 in some cases.

[0067] In this example, DC-DC converters 112a and 112b are also configured to receive electrical energy from AC charging input 114 (labeled "HV AC charger") and supply electrical energy to battery connection terminal 104 at a first voltage for charging the traction battery. An on-board charger 116 is coupled to DC-DC converters 112a and 112b. The on-board charger 116 is configured to receive AC current at AC charging input 114 and supply DC current to DC-DC converters 112a and 112b. In this example, OBC 116 is shown configured to accept an 800V or 400V input voltage. In this example, AC charging input 114 forms an external connection, for example, for connecting to an AC charging power source, and is connected to OBC 116, which receives AC input power and supplies DC power to DC-DC converters 112a and 112b. This example also illustrates a service test point 124, which is configured to allow electrical access for BEM connectivity testing. The purpose of service test point 124 is to enable safe and convenient disconnection of battery pack 106 from the vehicle. Such a test point 124 allows an operator to check that all connections to battery 106 have dropped to a safe operating voltage and can therefore be safely disconnected.

[0068] In this example, the traction battery 106 is shown electrically connected to battery connection terminals 104a and 104b, allowing the battery pack 106 to be connected to the power circuit 100. The traction battery 106 in this example includes a first plurality of battery cells 122a, a second plurality of battery cells 122b, and a battery control circuit (not shown). This battery control circuit selectively interconnects the first plurality of battery cells 122a and the second plurality of battery cells 122b in series to provide a first battery voltage at the battery output terminal 104b in a first operating mode, and selectively interconnects the first plurality of battery cells 122a and the second plurality of battery cells 122b in parallel to provide a second battery voltage at the battery output terminal 104b in a second operating mode. In this example, each of the first plurality of battery cells 122a and the second plurality of battery cells 122b is a 400V battery cell, the first battery voltage can be 800V, and the second battery voltage can be 400V.

[0069] Figure 6 It shows how to control, for example Figures 1 to 5The illustrated vehicle's electrical circuit control system 600 includes one or more controllers 608. The control system 600 is configured to control an electrical circuit 100, which includes: a charging input 102 for receiving electrical energy at a voltage equal to a first voltage or a second voltage for charging a traction battery 106 of the vehicle; a battery connection terminal 104 for electrically connecting to the traction battery 106 to supply electrical energy from the charging input 102 for charging the traction battery 106 at the first voltage or the second voltage, and for receiving electrical energy from the traction battery 106 to power one or more traction motors 108 of the vehicle at the second voltage; and a DC-DC converter 112 coupled to the charging input 102 and an output 110 for electrically connecting the DC-DC converter 112 to the vehicle's electrical bus for supplying power to one or more electrical units of the vehicle at an output voltage.

[0070] The control system 600 is configured to control the DC-DC converter 112 to receive electrical energy from the charging input 102 and to supply electrical energy to the output 110 at the output voltage while charging the traction battery 106 at a first voltage.

[0071] One or more controllers 608 may collectively include at least one electronic processor 612 having an electrical input 602 for receiving information from one or more sensors and / or one or more external controllers; and at least one electronic memory device 610 connected to the at least one electronic processor 612 and having instructions stored therein. The at least one electronic processor 612 may be configured to access the at least one memory device 610 and execute instructions thereon to cause the control system 600 to control the DC-DC converter according to the information. For example, an input instructing the DC-DC converter to receive electrical energy at a specific first voltage, such as 800V, may be provided to the input 602. The controller may then provide an output signal at the output 604 for transmission to the DC-DC converter to instruct it to provide power at, for example, 400V, and / or may provide signaling from the output 604 to the DC-DC converter to enable it to operate at an 800V input voltage and provide electrical energy at a 400V output voltage.

[0072] In an example where the power circuit 100 includes an AC charging input 114, the control system 600 can be configured to control the DC-DC converter 112 to receive electrical energy from the AC charging input 114 and to supply electrical energy to the battery connection terminal 104 at a first voltage for charging the traction battery 106. For example, an input instructing the DC-DC converter to receive AC power at a specific first voltage, such as 400V, can be provided to input 602. The controller can then provide an output signal at output 604 for transmission to the DC-DC converter to instruct the supply of AC power at 400V and / or to the DC-DC converter to operate at a 400V AC input voltage and supply power at a 12VDC output voltage.

[0073] Each controller 600 may include a computing device or control unit 608 having one or more electronic processors 612. (Vehicle - see [reference]) Figure 8 ) and / or its systems (see Figure 7 The controller 600 may include a single control unit 608 or electronic controller 600, or alternatively, different functions of the controller 600 may be embodied in or hosted in different control units 608 or controllers 600. A set of instructions may be provided, which, when executed, causes the controller 600 or control unit 608 to implement the control techniques (including the methods described herein). This set of instructions may be embedded in one or more electronic processors 612, or alternatively, may be provided as software to be executed by one or more electronic processors 612. For example, the first controller 608 may be implemented as software running on one or more electronic processors 612, and one or more other controllers 608 may also be implemented as software running on one or more electronic processors 612, or alternatively, as software running on the same one or more processors 612 as the first controller 608. However, it will be appreciated that other arrangements are also useful, and therefore, this disclosure is not intended to be limited to any particular arrangement. In any case, the above set of instructions may be embedded in a computer-readable storage medium (e.g., a non-transitory computer-readable storage medium), which may include any mechanism for storing information in a form readable by a machine or electronic processor / computing device, including but not limited to: magnetic storage media (e.g., floppy disk); optical storage media (e.g., CD-ROM); magneto-optical storage media; read-only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM and EEPROM); flash memory; or electrical media or other types of media for storing such information / instructions.

[0074] Figure 7 System 700 is shown, which includes an input terminal 702, for example, Figure 6 The control system 600 shown herein, for example, is as follows: Figure 4 and Figure 5 The battery assembly 150 and output terminal 704 shown are controlled by the control system 600.

[0075] Figure 8 A vehicle 800 is shown, which includes the electrical circuit 100 described above, the battery pack 150 described above, the control system 600 described above, or the system 700 described above. The vehicle may include an electrical bus, wherein the electrical bus includes an auxiliary power bus (e.g., a high-voltage (HV) bus) configured to provide electrical power to one or more auxiliary units of the vehicle 800 at a second voltage provided by the electrical circuit. Example vehicle 800 may be a passenger vehicle, also referred to as a passenger car or automobile, or in other examples, vehicle 800 may be an industrial vehicle. Vehicle 800 may be an electric vehicle (EV) or a hybrid electric vehicle (HEV). If vehicle 800 is an HEV, then vehicle 800 may be a plug-in HEV or a mild HEV. If vehicle 800 is a plug-in HEV, then vehicle 800 may be a series HEV or a parallel HEV. In a parallel HEV, the traction motor and the internal combustion engine may operate in parallel to provide traction torque simultaneously. In a series HEV, the internal combustion engine generates electricity, and the traction motor is dedicated to providing traction torque.

[0076] Figure 9 A method 900 for controlling the electrical circuitry of a vehicle as disclosed herein is illustrated. Method 900 includes controlling a DC-DC converter to: receive electrical energy 902 from a charging input; and simultaneously supply electrical energy 904 to an output at an output voltage while charging a traction battery at a first voltage.

[0077] Figure 9 The boxes shown may represent steps in method 900 and / or code segments in a computer program configured to control the electrical circuitry described above to perform the method steps. The description of a particular order of boxes does not necessarily imply a desired or preferred order, and the order and arrangement of boxes may vary. Furthermore, in other examples, some steps may be omitted or added. Therefore, this disclosure also includes computer software that, when executed, is configured to perform any of the methods disclosed herein, such as... Figure 9 The method shown. Optionally, the computer software is stored on a computer-readable medium and may be tangibly stored.

[0078] The examples disclosed herein allow for the charging of a vehicle's battery pack at a first voltage among a plurality of possible voltages, while providing power to one or more auxiliary units of the vehicle at one or more additional voltages, which may or may not match the charging voltage at the input. For example, the battery pack may be charged at 800V, while power is provided to the battery heater unit at 400V, and / or power is supplied to the vehicle's auxiliary units at 12V. Furthermore, the examples disclosed herein allow for the configuration of port voltages in multiple ways, which may be desirable for use in a variety of vehicle / vehicle configurations. These different voltage requirements for different vehicles can be described as "cross-vehicle requirements." Moreover, the configuration of the circuits described herein can be adapted "on the fly" by the user. For example, the vehicle battery can be charged using an 800V or 400V charger without requiring an update to the vehicle's hardware by using a means that allows switching between 400V and 800V to be acceptable at the circuit input. This cannot be done with existing topologies.

[0079] It will be appreciated that various changes and modifications may be made to the examples disclosed herein without departing from the scope of this application as defined by the appended claims.

[0080] As used herein, "module" refers to a unit or device that does not include certain parts / components that will be added by the final manufacturer or user.

[0081] As used herein, “connection” means direct or indirect “electrical interconnection.” Electrical interconnection need not be current-driven. In the case of control systems, the connection device can be operatively coupled to the extent that it can send and receive messages via appropriate communication devices.

[0082] The term "current" refers to electrical current. The term "voltage" refers to potential difference. The term "series" refers to electrical circuits connected in series. The term "parallel" refers to electrical circuits connected in parallel. The term "power" refers to electrical power. The term "charging" refers to the recharging of a battery. The term "winding" is synonymous with "coil" in the context of transformer windings and split windings. In an example where one of the split windings is connected in the circuit, for example, receiving / providing a lower voltage than if both split windings were connected in series in the circuit, it can be understood that the other split windings are not connected in the circuit, i.e., they are kept "floating".

[0083] Although various examples have been described in the foregoing paragraphs with reference to them, it should be understood that modifications may be made to the given examples without departing from the scope of the invention as set forth in the appended claims. Features described in the foregoing description may be used in combinations other than those explicitly described. Although functionality has been described with reference to certain features, these functions may be performed by other features, whether or not they are described. Although features have been described with reference to certain embodiments, these features may also exist in other embodiments, whether or not they are described.

[0084] Although the foregoing specification focuses on features deemed particularly important, it should be understood that the applicant claims protection for any patentable features or combinations thereof mentioned above and / or shown in the accompanying drawings, whether or not they have been specifically highlighted.

Claims

1. An electrical circuit for a vehicle, comprising: A charging input terminal is used to receive electrical energy at a voltage equal to a first voltage or a second voltage for charging the traction battery of the vehicle. A battery connection terminal is used to electrically connect to the traction battery to supply electrical energy from the charging input terminal for charging the traction battery at the first voltage or the second voltage, and to receive electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage. as well as A DC-DC converter coupled to the charging input and output, the output being used to electrically connect the DC-DC converter to the vehicle's electrical bus for providing power to one or more electrical units of the vehicle at an output voltage, the DC-DC converter being configured to receive electrical energy from the charging input and provide a stable output of electrical energy to the output at the output voltage, regardless of whether the traction battery is charged at the first voltage or the second voltage, such that the electrical units can operate at a voltage preferred for the electrical units while charging the traction battery at an available voltage.

2. The power circuit according to claim 1, wherein, The first voltage is higher than the second voltage.

3. The power circuit according to claim 1 or 2, wherein, The first voltage and the second voltage are non-overlapping ranges.

4. The power circuit according to claim 1 or 2, wherein, The output voltage is lower than the first voltage and the second voltage.

5. The power circuit according to claim 1 or 2, wherein, The output voltage is the second voltage.

6. The power circuit according to claim 1 or 2, comprising an AC charging input terminal, wherein, The DC-DC converter is configured to receive electrical energy from the AC charging input and to supply electrical energy to the battery connection terminal at the first voltage for charging the traction battery.

7. The power circuit according to claim 6, wherein, The output terminal is used to electrically connect the DC-DC converter to the vehicle's electrical bus for supplying power to one or more auxiliary electrical units of the vehicle at the output voltage while charging the traction battery via AC charging.

8. The power circuit of claim 1 or 2, comprising an on-board charger coupled to the DC-DC converter, the on-board charger being configured to receive AC current and provide DC current to the DC-DC converter.

9. A battery assembly comprising a traction battery and a power circuit according to any one of claims 1 to 8, wherein, The traction battery includes a battery input / output terminal, wherein the battery input / output terminal is electrically connected to the battery connection terminal.

10. The battery assembly according to claim 9, wherein, The traction battery includes a first plurality of battery cells, a second plurality of battery cells, and a battery control circuit. The battery control circuit selectively interconnects the first plurality of battery cells and the second plurality of battery cells in series to provide a first battery voltage at the battery output terminal in a first operating mode, and selectively interconnects the first plurality of battery cells and the second plurality of battery cells in parallel to provide a second battery voltage at the battery output terminal in a second operating mode.

11. A control system for controlling an electrical circuit of a vehicle, the control system comprising one or more controllers, the electrical circuit comprising: A charging input terminal is used to receive electrical energy at a voltage equal to a first voltage or a second voltage for charging the traction battery of the vehicle. as well as A battery connection terminal is used to electrically connect to the traction battery to supply electrical energy from the charging input terminal for charging the traction battery at the first voltage or the second voltage, and to receive electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage. as well as A DC-DC converter coupled to the charging input and output, wherein the output is used to electrically connect the DC-DC converter to the vehicle's electrical bus to provide power to one or more electrical units of the vehicle at an output voltage; The control system is configured to control the DC-DC converter in the power circuit to: Receive electrical energy from the charging input terminal, and While charging the traction battery with the first voltage, the electrical unit provides a stable output of electrical energy to the output terminal with the output voltage, enabling the electrical unit to operate at a voltage preferred for the electrical unit while charging the traction battery with an available voltage.

12. A system comprising: The battery assembly according to claim 9 or 10; as well as The control system according to claim 11.

13. A vehicle comprising a power circuit according to any one of claims 1 to 8, or a battery assembly according to claim 9 or 10, or a control system according to claim 11, or a system according to claim 12.

14. A method for controlling an electrical circuit for a vehicle, the electrical circuit comprising: A charging input terminal is used to receive electrical energy at a voltage equal to a first voltage or a second voltage for charging the traction battery of the vehicle. as well as A battery connection terminal is used to electrically connect to the traction battery to supply electrical energy from the charging input terminal for charging the traction battery at the first voltage or the second voltage, and to receive electrical energy from the traction battery to power one or more traction motors of the vehicle at the second voltage. as well as A DC-DC converter coupled to the charging input and output, wherein the output is used to electrically connect the DC-DC converter to the vehicle's electrical bus to provide power to one or more electrical units of the vehicle at an output voltage; The method includes controlling the DC-DC converter to: Receive electrical energy from the charging input terminal; and While charging the traction battery with the first voltage, the electrical unit provides a stable output of electrical energy to the output terminal with the output voltage, enabling the electrical unit to operate at a voltage preferred for the electrical unit while charging the traction battery with an available voltage.

15. A computer software, which, when executed, is configured to perform the method according to claim 14.

16. The computer software according to claim 15, wherein, The computer software is stored on a computer-readable medium.

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