Multi-functional vehicle battery charger module

Abstract

A multi-functional on-board charge module (OBCM) operable to charge a battery pack using a wide variety of off-board charging systems, such as enabling the OBCM to charge the battery pack using power provided from different types of direct current (DC), single-phase alternating current (AC), and / or three-phase AC off-board charging systems.

Description

Technical Field

[0001] This disclosure relates to a multifunctional battery charger module, such as, but not limited to, a multifunctional on-board charger module (OBCM), which is operable to facilitate the charging of a battery pack or other rechargeable energy storage system (RESS) operable to provide power for the operation of an electric vehicle. Background Technology

[0002] Electric vehicles can be considered a type of vehicle that relies on a battery pack to provide power to a motor, which then converts the electricity into mechanical power. This motor is typically used in conjunction with a propulsion system configured to drive the electric vehicle. Some electric vehicles include fuel cells, generators, and / or other types of onboard regenerative charging systems and devices to facilitate charging the battery pack while driving the vehicle. However, some electric vehicles may lack such onboard regenerative charging devices, and / or the vehicle operator may prefer to charge the battery pack without relying on onboard regenerative devices, for example, if charging the battery pack using a non-onboard charging system is more cost-effective or faster, or if such charging may be necessary due to the onboard regenerative charging system running out of fuel or otherwise failing to meet the battery pack's charging needs.

[0003] Recognizing the need for off-vehicle charging, a wide variety of suppliers, utility providers, and others have developed numerous off-vehicle charging systems. However, these systems can present problems; for some types of electric vehicles, they may be incompatible with specific types of off-vehicle charging systems. For example, some electric vehicles may be incompatible with certain types of DC, single-phase AC, and / or three-phase AC off-vehicle charging systems. Summary of the Invention

[0004] One non-limiting aspect of this disclosure relates to a multi-functional on-board charging module (OBCM) capable of operating to charge a battery pack using a variety of off-board charging systems, such as enabling the OBCM to charge the battery pack using power supplied from different types of DC, single-phase AC, and / or three-phase AC off-board charging systems.

[0005] One non-limiting aspect of this disclosure relates to a multi-functional on-board battery charger module (OBCM) for charging a battery pack using power derived from multiple off-board charging systems. The battery pack may be configured to supply power to the motor of an electric vehicle, optionally wherein the motor converts the power into mechanical power for driving the electric vehicle. The OBCM may include a boost converter and an isolation converter, the boost converter being operable to boost a charging input to a boost output operable for charging the battery pack, and the isolation converter being operable to electrically isolate the boost converter from the battery pack and to convert the boost output to an isolated output operable for charging the battery pack. The OBCM may also include an output filter operable to reduce noise within one of the boost output and the isolated output, optionally wherein the filtered output of the output filter interfaces one of the boost output and the isolated output with the battery pack. The OBCM may further include an isolation bypass circuit capable of operating between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter, and in the isolation connection state, the boost output is connected to the isolation input of the isolation converter. The OBCM may also further include a battery bypass circuit capable of operating between a battery connection state and a battery disconnect state. In the battery connection state, the charging input is connected to the battery pack via a direct connection in the bypass of the boost converter and the isolation converter, and in the battery disconnect state, this direct connection is disconnected.

[0006] The boost converter can operate to generate a boost output as a high-voltage DC output when the charging input is any of the following: a lower voltage DC input below the high-voltage DC output, a single-phase AC input, or a three-phase AC input. The boost converter can be configured to generate an 800V high-voltage DC output when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V, and the three-phase AC input is between 170-265V.

[0007] The isolation bypass circuit may include a relay within an isolation connection between the boost output and the filter input, wherein the isolation bypass state occurs when the relay is in a closed state, and the isolation connection state occurs when the relay is in an open state.

[0008] The battery bypass circuit may include a relay between a directly connected connection input and a connection output, wherein the battery connection state occurs when the relay is in a closed state, and the battery disconnection state occurs when the relay is in an open state.

[0009] A boost converter may include multiple switches and any number of inductors arranged in a multi-phase totem-pole power factor correction (PFC) configuration. A pulse width modulation (PWM) controller may be operable to set the switching frequency and duty cycle of each of the switches to control the boost from the charging input to the boost output.

[0010] An isolated converter comprises multiple switches and any number of inductors arranged in a CLLLC converter configuration. A pulse width modulation (PWM) controller is operable to set the switching frequency and duty cycle for each of the switches to control the conversion from boost output to isolated output.

[0011] The OBCM may include an input filter that is operable to reduce noise within the charging input, wherein the filter output of the input filter interfaces the charging input with the boost converter.

[0012] The OBCM may include an electrical connector configured to electrically interface an input filter and bypass circuitry with an off-board charging system. The electrical connector may include a DC connection configured for electrical connection to a DC charging system of the off-board charging system. The electrical connector may also include an AC connection configured for electrical connection to a single-phase or three-phase AC charging system of the off-board charging system. The AC connection may include multiple electrical inputs and multiple switches, wherein the switches are individually operable between open and closed positions to selectively connect the inputs to the input filter depending on whether the AC connection is electrically connected to a single-phase or three-phase AC charging system.

[0013] One non-limiting aspect of this disclosure relates to a multi-functional on-board battery charger module (OBCM) for charging a battery pack using power derived from multiple off-board charging systems. The OBCM may include an electrical connector having a DC (DC) connection configured for electrical connection to a DC charging system of the off-board charging systems and an AC (AC) connection configured for electrical connection to a single-phase AC charging system and a three-phase AC charging system of the off-board charging systems. The OBCM may additionally include a boost converter and an isolation converter, the boost converter being operable to boost the charging input to a boost output operable for charging the battery pack, and the isolation converter being operable to electrically isolate the boost converter from the battery pack and to convert the boost output to an isolated output operable for charging the battery pack. The OBCM may also include an output filter operable to mitigate noise within one of the boost output and the isolated output, wherein the filtered output of the output filter interfaces one of the boost output and the isolated output with the battery pack. The OBCM may further include an isolation bypass circuit capable of operating between an isolation bypass state and an isolation connection state, wherein the isolation bypass state connects the boost output to the filter input of the output filter in the bypass of the isolation converter, and the isolation connection state connects the boost output to the isolation input of the isolation converter. The OBCM may also include a battery bypass circuit capable of operating between a battery connection state and a battery disconnect state, wherein the battery connection state connects the charging input to the battery pack via a direct connection in the bypass of the boost converter and the isolation converter, and the battery disconnect state disconnects this direct connection.

[0014] An AC connection may include multiple electrical inputs and multiple switches, which can be operated individually between open and closed positions to selectively connect inputs to charging inputs depending on whether the AC connection is electrically connected to a single-phase AC charging system or a three-phase AC charging system.

[0015] A boost converter may include multiple switches and any number of inductors arranged in a multiphase totem-pole power factor correction (PFC) configuration. An isolation converter may include multiple switches and any number of inductors arranged in a CLLLC converter configuration. A pulse width modulation (PWM) controller may be operable to set the switching frequency and duty cycle for each of the switches in the boost and isolation converters to control the boost and conversion of the charging input.

[0016] One non-limiting aspect of this disclosure relates to a multi-functional on-board battery charger module (OBCM). The OBCM may include a boost converter operable to boost a charging input to a boost output, an isolation converter operable to electrically isolate the boost converter from a battery pack and to convert the boost output to an isolated output, and an output filter operable to mitigate noise within the output generated by either the boost output or the isolated output. The OBCM may additionally include an isolation bypass circuit operable between an isolation bypass state and an isolation connection state, wherein the isolation bypass state connects the boost output to the filter input of the output filter in a bypass of the isolation converter, and the isolation connection state connects the boost output to the isolated input of the isolation converter. The OBCM may also include a battery bypass circuit operable between a connection state and a disconnect state, wherein the battery connection state connects the charging input to the output via a direct connection in the bypasses of the boost converter and the isolation converter, and the disconnect state disconnects the direct connection.

[0017] The boost converter can operate to generate a boost output as a high-voltage DC output when the charging input is any of the following: a lower voltage DC input below the high-voltage DC output, a single-phase AC input, or a three-phase AC input. The boost converter can be configured to generate an 800V high-voltage DC output when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V, and the three-phase AC input is between 170-265V.

[0018] This disclosure also relates to the following technical solutions:

[0019] 1. A multi-functional on-board battery charger module (OBCM) for charging a battery pack using power derived from multiple off-board charging systems, the battery pack being configured to supply power to a motor of an electric vehicle, the motor converting the power into mechanical power for driving the electric vehicle, the OBCM comprising:

[0020] A boost converter, operable to boost a charging input to a boost output, the boost output operable to charge the battery pack;

[0021] An isolation converter is operable to electrically isolate the boost converter from the battery pack and to convert the boost output into an isolated output operable to charge the battery pack.

[0022] An output filter is operable to reduce noise in one of the boost output and the isolated output, and the filter output of the output filter interfaces one of the boost output and the isolated output with the battery pack.

[0023] An isolated bypass circuit operates between an isolated bypass state and an isolated connection state, wherein the isolated bypass state connects the boost output to the filter input of the output filter in the bypass of the isolated converter, and the isolated connection state connects the boost output to the isolated input of the isolated converter; and

[0024] A battery bypass circuit is operable between a battery connected state and a battery disconnected state. In the battery connected state, the charging input is connected to the battery pack via a direct connection in the bypass of the boost converter and the isolation converter. In the battery disconnected state, the direct connection is disconnected.

[0025] 2. According to the OBCM of technical solution 1, the boost converter is operable to generate the boost output as a high voltage DC output when the charging input is any one of a lower voltage DC input below the high voltage DC output, a single-phase AC input, and a three-phase AC input.

[0026] 3. The OBCM according to technical solution 2, wherein the boost converter is configured to generate the high-voltage DC output of 800V when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V and the three-phase AC input is between 170-265V.

[0027] 4. The OBCM according to technical solution 1, wherein the isolation bypass circuit includes a relay in the isolation connection between the boost output and the filter input, the isolation bypass state occurs when the relay is in the closed state, and the isolation connection state occurs when the relay is in the open state.

[0028] 5. The OBCM according to technical solution 1, wherein the battery bypass circuit includes a relay between the directly connected connection input and connection output, the battery connection state occurs when the relay is in a closed state, and the battery disconnection state occurs when the relay is in an open state.

[0029] 6. The OBCM according to technical solution 1, wherein the boost converter includes a plurality of switches and any plurality of inductors arranged in a multiphase totem pole power factor correction (PFC) configuration.

[0030] 7. The OBCM according to technical solution 6 further includes a pulse width modulation (PWM) controller, which is operable to set the switching frequency and duty cycle for each of the switches to control the boost of the charging input to the boost output.

[0031] 8. The OBCM according to technical solution 1, wherein the isolation converter includes a plurality of switches and any plurality of inductors arranged in a CLLLC converter configuration.

[0032] 9. The OBCM according to technical solution 8 further includes a pulse width modulation (PWM) controller, which is operable to set the switching frequency and duty cycle for each of the switches to control the conversion of the boost output to the isolated output.

[0033] 10. The OBCM according to technical solution 1 further includes an input filter, the input filter being operable to reduce noise in the charging input, and the filter output of the input filter connecting the charging input to the boost converter.

[0034] 11. The OBCM according to technical solution 10 further includes an electrical connector configured to electrically connect the input filter and the bypass circuit to the off-board charging system.

[0035] 12. The OBCM according to technical solution 11, wherein the electrical connector includes a DC connection configured for electrical connection to the DC charging system of the off-board charging system.

[0036] 13. The OBCM according to technical solution 12, wherein the electrical connector includes an AC connection configured for electrical connection to a single-phase AC charging system and a three-phase AC charging system of the off-board charging system.

[0037] 14. The OBCM according to technical solution 13, wherein the AC connection includes multiple electrical inputs and multiple switches, the switches being individually operable between an open-circuit position and a closed-circuit position to selectively connect the inputs to the input filter depending on whether the AC connection is electrically connected to the single-phase AC charging system or the three-phase AC charging system.

[0038] 15. A multi-functional on-board battery charger module (OBCM) for charging a battery pack using power derived from multiple off-board charging systems, comprising:

[0039] An electrical connector having a DC (DC) connection configured for electrical connection to a DC charging system of the off-board charging system and an AC (AC) connection configured for electrical connection to a single-phase AC charging system and a three-phase AC charging system of the off-board charging system.

[0040] A boost converter, operable to boost a charging input to a boost output, the boost output operable to charge the battery pack;

[0041] An isolation converter is operable to electrically isolate the boost converter from the battery pack and to convert the boost output into an isolated output operable to charge the battery pack.

[0042] An output filter is operable to reduce noise in one of the boost output and the isolated output, and the filter output of the output filter interfaces one of the boost output and the isolated output with the battery pack.

[0043] An isolation bypass circuit is operable between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter. In the isolation connection state, the boost output is connected to the isolated input of the isolation converter.

[0044] A battery bypass circuit is operable between a battery connected state and a battery disconnected state. In the battery connected state, the charging input is connected to the battery pack via a direct connection in the bypass of the boost converter and the isolation converter. In the battery disconnected state, the direct connection is disconnected.

[0045] 16. According to the OBCM of technical solution 15, the AC connection includes multiple electrical inputs and multiple switches, the switches being individually operable between an open-circuit position and a closed-circuit position to selectively connect the inputs to the charging inputs depending on whether the AC connection is electrically connected to the single-phase AC charging system or the three-phase AC charging system.

[0046] 17. The OBCM according to technical solution 16, wherein:

[0047] The boost converter includes multiple switches and any multiple inductors arranged in a multiphase totem pole power factor correction (PFC) configuration;

[0048] The isolation converter includes a plurality of switches and any plurality of inductors arranged in a CLLLC converter configuration; and

[0049] A pulse width modulation (PWM) controller, operable to set the switching frequency and duty cycle for each of the switches of the boost converter and the isolation converter to control the boost and conversion of the charging input.

[0050] 18. A multi-functional on-board battery charger module (OBCM), comprising:

[0051] A boost converter, operable to boost a charging input to a boost output;

[0052] An isolation converter, operable to electrically isolate the boost converter from the battery pack and to convert the boost output to an isolated output;

[0053] An output filter, operable to mitigate noise within the output generated by either the boost output or the isolated output;

[0054] An isolation bypass circuit is operable between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter. In the isolation connection state, the boost output is connected to the isolated input of the isolation converter.

[0055] A battery bypass circuit capable of operating between a connected state and a disconnected state, wherein the connected state connects the charging input to the output via a direct connection in the bypass of the boost converter and the isolation converter, and the disconnected state disconnects the direct connection.

[0056] 19. The OBCM according to technical solution 18, wherein when the charging input is any one of a lower voltage DC input below the high voltage DC output, a single-phase AC input, and a three-phase AC input, the boost converter is operable to generate the boost output as a high voltage DC output.

[0057] 20. The OBCM according to technical solution 19, wherein the boost converter is configured to generate the high-voltage DC output of 800V when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V and the three-phase AC input is between 170-265V.

[0058] The above-described features and advantages, as well as other features and advantages of this teaching, will become apparent when considered in conjunction with the accompanying drawings, based on the following detailed description of the mode used to perform this teaching. It should be understood that although the following drawings and embodiments may be described separately, their individual features may be combined into additional embodiments. Attached Figure Description

[0059] The accompanying drawings are incorporated in and form a part of this specification. The drawings illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0060] Figure 1The illustration shows a charging system having an on-board charger module (OBCM) according to a non-limiting aspect of this disclosure.

[0061] Figure 2 The illustration shows a schematic diagram of an OBCM according to a non-limiting aspect of the present disclosure.

[0062] Figure 3 The illustration shows a component diagram of an OBCM according to a non-limiting aspect of this disclosure.

[0063] Figure 4 The illustration shows a flowchart of a method for charging a multi-functional vehicle battery according to a non-limiting aspect of the present disclosure. Detailed Implementation

[0064] Specific embodiments of this disclosure are disclosed herein as requested; however, it should be understood that the disclosed embodiments are merely examples of this disclosure, which may be embodied in various forms and alternative forms. The accompanying drawings are not necessarily to scale, and some features may be enlarged or reduced to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to utilize this disclosure in various ways.

[0065] Figure 1 A charging system 10 according to a non-limiting aspect of this disclosure is illustrated. The charging system 10 is primarily described in relation to its inclusion of a multi-function on-board charging module (OBCM) 12 for charging a battery pack 16 contained within an electric vehicle 18 using power supplied from multiple different types of off-board charging systems 22. The use of the described OBCM 12 in charging the battery pack 16 is presented for illustrative and non-limiting purposes, as this disclosure fully contemplates the ability of the OBCM 12 to operate to facilitate charging other rechargeable energy storage systems (RESS), including those contained in other types of automobiles, vehicles, devices, etc. For the sake of brevity, system 10 illustrates a single off-board charging system 22, as the illustrated off-board charging system 22 is intended to represent multiple different types of off-board charging systems that can be used to facilitate charging the battery pack 16. The off-vehicle charging system 22 shown in the diagram represents those typically found in charging stations, homes, utilities, the power grid, and other locations accessible to electric vehicles 18 for charging, which can be collectively referred to as Electric Vehicle Power Supply Equipment (EVSE) or Commercial / Residential Electric Vehicle 18 Charging Station (EVCS).

[0066] Electric vehicle 18 may include a motor, powertrain, or other type of propulsion system 24 capable of operating to convert electricity supplied from battery pack 16 into mechanical power sufficient to drive electric vehicle 18. While electric vehicle 18 may include fuel cells, generators, and / or other types of on-board regenerative charging systems (not shown) to facilitate charging battery pack 16, this disclosure is primarily described in relation to the use of OBCM 12 for charging battery pack 16 using electricity supplied from various off-board charging systems 22. Using OBCM 12 to charge battery pack 16 by supplying electricity from various off-board charging systems 22 may be advantageous when electric vehicle 18 lacks an on-board regenerative charging device and / or when the vehicle operator prefers to charge battery pack 16 without relying on an on-board regenerative device. Charging battery pack 16 using off-board charging systems 22 may also be more cost-effective or faster, or necessary due to the on-board regenerative charging system running out of fuel or otherwise failing to meet the battery pack's charging needs.

[0067] Recognizing the need for off-vehicle charging, various suppliers, utility providers, etc., have developed a wide range of different types and configurations of off-vehicle charging systems 22, including those supplying power with direct current (DC), single-phase alternating current (AC), and / or three-phase AC input. While off-vehicle charging systems 22 are illustrated as stationary infrastructure, some off-vehicle charging systems 22 are mobile, including those integrally mounted on other vehicles or devices. For example, as those skilled in the art will understand, when the charging system of another electric vehicle is used to supply power to the OBCM 12 for the purpose of charging the battery pack 16, that other electric vehicle can be considered an off-vehicle charging system 22. Therefore, this disclosure contemplates that off-vehicle charging systems 22 include each type of power supply capable of providing power that can be used with the OBCM 12.

[0068] For the purposes of this disclosure, the off-board charging system 22 may be considered alone as a device not on the electric vehicle 18, capable of supplying power to the OBCM 12 to facilitate charging of the battery pack 16. However, as described in more detail below, the OBCM 12 may include a bidirectional configuration, wherein the OBCM 12 may be configured to receive a power supply from the off-board charging system 22 for charging the battery pack 16, and is also configured to supply power from the battery pack 16 to the off-board charging system 22 or other devices. Therefore, this disclosure contemplates its use and application in conjunction with various types of charging activities, and more specifically, the use and application of the OBCM 12 in conjunction with various types of charging activities, including vehicle-to-vehicle (V2V) DC fast charging (DCFC), AC charging level 1, 2, or 3 charging, vehicle-to-grid (V2G), vehicle-to-externally connected electrical loads (vehicle-to-load or V2L), vehicle-to-grid (V2G), etc., which can be collectively referred to as vehicle-to-anything (V2X).

[0069] Figure 2 A schematic diagram 32 of an OBCM 12 according to a non-limiting aspect of the present disclosure is illustrated. The OBCM 12 may include an electrical connector 34 for electrical interfacing with an off-board charging system 22. The electrical connector 34 includes a DC connection 36 for connection to the DC output of the DC off-board charging system 22 and an AC connection 38 for connection to the AC output of the AC off-board charging system 22. The electrical connection 34 may be connected to a DC socket 40 (see...). Figure 1 Together with the AC socket 48, the DC socket 40 is configured to connect to the connector 42, which is associated with the charging cable 44 of the off-board charging system 22 supplying DC power; and the AC socket 48 is operable to connect to the connector 42 of the off-board charging system 22 supplying AC power, wherein the AC socket 48 is configured to support both single-phase and three-phase AC. The illustrated configurations of the DC and AC connections 36, 38 are presented for illustrative purposes, as this disclosure fully contemplates other connection methods employed, including the use of a single DC or AC connection 36, 38, optionally wherein the AC connection 38 supports either single-phase or three-phase AC, which is the opposite of the illustrated configuration that simultaneously supports both single-phase and three-phase AC.

[0070] Power supply from one of the off-board charging systems 22 can be delivered via one of the DC or AC connections 36, 38 to act as a charging input 52 to the OBCM 12. Optionally, an input filter 54 may be included and configured to reduce noise within the charging input 52, wherein the filter output 56 of the input filter 54 interfaces the charging input 52 with a boost converter 60. The boost converter 60 may be configured to boost the charging input 52 to a boost output 64 sufficient to charge the battery pack 16. One or more capacitors 70 may be included to smooth the boost output 64. An isolation converter 76 may be configured to electrically isolate the boost converter 60 from the battery pack 16 and convert the boost output 64 to an isolated output 78 sufficient to charge the battery pack 16. An isolation bypass circuit 80 has an isolation relay 82 disposed within an isolation connection 84, and the isolation bypass circuit 80 may be configured to selectively bypass the isolation converter 76. The isolation relay 82 is controllable between an open-circuit state and a closed-circuit state, wherein the closed-circuit state corresponds to an isolation bypass state in which the boost output 64 bypasses the isolation converter 76, and the open-circuit state corresponds to an isolation connection state in which the boost output 64 is connected to the isolation input 86 of the isolation converter 76. One or more capacitors 88 may be included to smooth the isolation output 78.

[0071] Optionally, an output filter 90 may be included, configured to mitigate noise in one of the boost and isolated outputs 64, 78 depending on whether the isolation bypass circuit 80 is in an isolated bypass state or an isolated connection state, wherein the filter output 92 of the output filter 90 interfaces one of the boost and isolated outputs 64, 78 with the battery pack 16. A battery bypass circuit 96 may be included, having multiple battery relays 98, 100 and multiple individual conductors 102, 104, to selectively bypass filters 54, 90 and boost and isolated converters 60, 76 to provide a direct connection between DC connection 36 and battery pack 16, i.e., to provide a direct connection between a DC power supply and battery pack 16, such as to provide DCFC. Battery relays 98, 100 may be controllable between open-circuit and closed-circuit states, wherein a battery-connected state corresponds to battery relays 98, 100 being in a closed-circuit state, and a battery-disconnected state corresponds to battery relays 98, 100 being in an open-circuit state. Figure 1 As shown, a charging controller 106 may be included to control the isolation and battery relays 82, 98, 100 and to instruct the operation of the OBCM 12 to facilitate bidirectional charging and discharging of the battery pack 16.

[0072] Figure 3A component diagram 110 of an OBCM 12 according to a non-limiting aspect of this disclosure is illustrated. DC connection 36 may include multiple DC inputs 114, 116, selectively coupled to boost converter 60 via a first filter 54. AC connection 38 may include multiple AC inputs 118, 120, 122, 124, selectively coupled to boost converter 60 via a first filter 54 and multiple input relays 118, 120, 122, 124. Charging controller 106 may be configured to detect the type of power supplied via a connection to one of the off-board charging systems 22 and, based thereon, selectively actuate input relays 140, 142, 144, 146 between open / closed and closed / open states. Input and output filters 54, 90 may be configured as electromagnetic interference (EMI) filters. Boost converter 60 may include multiple boost switches S and multiple boost inductors U arranged in a multiphase totem-pole power factor correction (PFC) configuration. The isolation converter 76 may include a plurality of isolation switches X, a plurality of isolation inductors L, and a transformer T arranged in a CLLLC converter configuration.

[0073] This disclosure fully contemplates other boost and isolation converters 60, 76 with configurations sufficient to facilitate the operation contemplated herein; and the OBCM 12 may optionally include more or fewer illustrated components, such as omitting input and / or output filters 54, 90, and / or having other configurations for input relays 140, 142, 144, 146. Relays 82, 98, 100, 140, 142, 144, 146 may be mechanical relays, solid-state relays, or other types of relays capable of being actuated between open / open and closed / open states (e.g., between on and off states) according to signals, commands, voltages, etc., issued by or cooperating with the charging controller 106. Switches S, X may be metal-oxide-semiconductor field-effect transistors (MOSFETs), etc., capable of being controlled between open / open and closed / open states according to signals, commands, voltages, etc., issued by or cooperating with the charging controller 106. The charging controller 106 may include a pulse width modulation (PWM) controller and / or a plurality of corresponding non-transitory instructions stored on an associated computer-readable storage medium, which, when executed by a processor, may be sufficient to control the OBCM 12 as described herein, including controlling relays 82, 98, 100, 140, 142, 144, 146 and switches S, X between open and closed states, and controlling the switching frequency and duty cycle of switches S, X to facilitate manipulation of the power supply in a manner contemplated herein.

[0074] Figure 4A flowchart 150 illustrating a method for charging a multi-functional on-board battery according to a non-limiting aspect of this disclosure is shown. The method is primarily described in relation to charging a battery pack 16 using an OBCM 12; however, as stated above, this disclosure fully envisions controlling the OBCM 12 to facilitate bidirectional activity, whereby the OBCM 12 can be used to charge non-vehicle devices, i.e., not receiving power from a complex charging system 22, but rather providing power to it. A non-limiting aspect of this disclosure envisions the battery pack 16 as a high-voltage battery pack, such as one operating at 800V DC, wherein the non-vehicle charging system is configured to provide power at 800V DC, 400V DC (or other lower DC voltages), 85-265V single-phase AC, and / or 170-265V three-phase AC. However, these power levels and types are presented for illustrative purposes to illustrate levels and types typically used with electric vehicles, as the versatility of the OBCM 12 enables it to support a wider range of power transfers beyond the specific values ​​mentioned above.

[0075] Box 152 relates to determining the connection type between OBCM 12 and the off-board charging system 22, such as by querying the off-board charging system 22 via controller 104 to determine the type of power to be supplied from the off-board charging system 22. Box 154 relates to selecting or setting a state corresponding to each of relays 82, 98, 100, 140, 142, 144, 146, i.e., selectively opening / closing and closing / opening each of the relays. Exemplary states of each of relays 82, 98, 100, 140, 142, 144, 146 are shown below based on a representative power supply.

[0076]

[0077]

[0078] Block 156 relates to controlling the flow of power through OBCM 12, such as from one of the off-board charging systems 22 to battery pack 16. When a direct connection is provided between the off-board charging system 22 and battery pack 16, i.e., when the off-board charging system 22 can directly provide a high voltage (e.g., 800V DC) for use by the battery pack, each of the control switches S and X is in an off / open state; otherwise, each of the switches S and X can be controlled according to a PWM signal, i.e., the switching frequency and duty cycle of each of the switches S and X can be set to facilitate the supply of 800V DC to the battery pack, wherein each of the switches S and X is controlled differently according to the charging input. For example, switch S of boost converter 60 can be PWM controlled such that boost output 64 corresponds to the desired charging voltage for battery pack 16, i.e., 800V DC. Switch X of isolation converter 76 can be PD opium control such that it switches boost output 64 and isolates it from isolation output 78.

[0079] The terms “comprising,” “including,” and “having” are non-exclusive and therefore explicitly state the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Where possible, the order of steps, processes, and operations may be changed, and additional or alternative steps may be employed. As used herein, the term “or” includes any and all combinations of the associated listed items. The term “any of…” is understood to include any possible combination of the referred items, including “any” of the referred items. “A,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one of the items. Multiple such items may be present unless the context clearly indicates otherwise. The numerical values ​​of all parameters (e.g., the numerical values ​​of parameters of quantity or condition), unless otherwise expressly indicated or clearly understood from the context (including the appended claims), shall be understood to be modified in all cases by the term “about” regardless of whether “about” actually precedes the numerical value. Components “configured to” perform a specific function are capable of performing that specific function without modification, rather than merely having the possibility of performing that specific function after further modification. In other words, the hardware described, when explicitly configured to perform a specific function, is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that specific function.

[0080] While various embodiments have been described, this description is intended to be exemplary and not restrictive; and it will be apparent to those skilled in the art that many other embodiments and implementations are possible within the scope of these embodiments. Unless specifically limited, any feature of any embodiment may be used in combination with or in lieu of any other feature or element in any other embodiment. Therefore, the embodiments are not limited except as provided in the appended claims and their equivalents. Furthermore, various modifications and changes may be made within the scope of the appended claims. Although several modes for carrying out many aspects of this teaching have been described in detail, those skilled in the art will recognize various alternative aspects for carrying out this teaching within the scope of the appended claims. It is intended that everything contained in the foregoing description or shown in the drawings should be construed as an illustration and example of the entire range of alternative embodiments, and those skilled in the art will recognize these alternative embodiments as implied, structurally and / or functionally equivalent, or otherwise apparent based on the included content, and are not limited to those embodiments explicitly depicted and / or described.

Claims

1. A multifunctional on-board battery charger module for charging a battery pack using power derived from multiple off-board charging systems, the battery pack being configured to supply power to a motor of an electric vehicle, the motor converting the power into mechanical power for driving the electric vehicle, the multifunctional on-board battery charger module comprising: A boost converter, operable to boost a charging input to a boost output, the boost output operable to charge the battery pack; An isolation converter is operable to electrically isolate the boost converter from the battery pack and to convert the boost output into an isolated output operable to charge the battery pack. An output filter is operable to reduce noise in one of the boost output and the isolated output, and the filter output of the output filter interfaces one of the boost output and the isolated output with the battery pack. An isolation bypass circuit is provided, which is operable between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter, and in the isolation connection state, the boost output is connected to the isolation input of the isolation converter. and A battery bypass circuit is provided, operable between a battery connected state and a battery disconnected state. In the battery connected state, the charging input is directly connected to the battery pack via a bypass connection between the boost converter and the isolation converter. In the battery disconnected state, this direct connection is disconnected. The isolation bypass circuit includes a relay within an isolation connection between the boost output and the filter input. The isolation bypass state occurs when the relay is in a closed state, and the isolation connection state occurs when the relay is in an open state.

2. The multi-functional vehicle battery charger module according to claim 1, wherein, The boost converter is capable of operating to generate the boost output as a high-voltage DC output when the charging input is any of the following: a lower voltage DC input below the high-voltage DC output, a single-phase AC input, or a three-phase AC input.

3. The multi-functional vehicle battery charger module according to claim 2, wherein, The boost converter is configured to generate the high-voltage DC output of 800V when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V, and the three-phase AC input is between 170-265V.

4. The multi-functional vehicle battery charger module according to claim 1, wherein, The battery bypass circuit includes a relay between the directly connected input and the connected output, wherein the battery connection state occurs when the relay is in a closed state and the battery disconnection state occurs when the relay is in an open state.

5. The multifunctional vehicle battery charger module according to claim 1, wherein, The boost converter includes multiple switches and any number of inductors arranged in a multiphase totem pole power factor correction configuration.

6. The multi-functional vehicle battery charger module according to claim 5 further includes a pulse width modulation controller operable to set the switching frequency and duty cycle for each of the switches to control the boost of the charging input to the boost output.

7. The multi-functional vehicle battery charger module according to claim 1, wherein, The isolation converter includes a plurality of switches and any plurality of inductors arranged in a CLLLC converter configuration.

8. The multi-functional vehicle battery charger module according to claim 7 further includes a pulse width modulation controller operable to set the switching frequency and duty cycle for each of the switches to control the conversion of the boost output to the isolated output.

9. The multi-functional vehicle battery charger module according to claim 1 further includes an input filter, the input filter being operable to reduce noise in the charging input, and the filter output of the input filter connecting the charging input to the boost converter.

10. The multi-functional vehicle battery charger module according to claim 9 further includes an electrical connector configured to electrically connect the input filter and the bypass circuit to the off-board charging system.

11. The multifunctional vehicle battery charger module according to claim 10, wherein, The electrical connector includes a DC connection configured for electrical connection to the DC charging system of the off-board charging system.

12. The multifunctional vehicle battery charger module according to claim 11, wherein, The electrical connector includes an AC connection configured for electrical connection to the single-phase AC charging system and the three-phase AC charging system of the off-board charging system.

13. The multifunctional vehicle battery charger module according to claim 12, wherein, The AC connection includes multiple electrical inputs and multiple switches, which are individually operable between open and closed positions to selectively connect the electrical inputs to the input filter depending on whether the AC connection is electrically connected to the single-phase AC charging system or the three-phase AC charging system.

14. A multi-functional on-board battery charger module for charging a battery pack using power derived from multiple off-board charging systems, comprising: An electrical connector having a DC connection configured for electrical connection to a DC charging system of the off-board charging system and an AC connection configured for electrical connection to a single-phase AC charging system and a three-phase AC charging system of the off-board charging system. A boost converter, operable to boost a charging input to a boost output, the boost output operable to charge the battery pack; An isolation converter is operable to electrically isolate the boost converter from the battery pack and to convert the boost output into an isolated output operable to charge the battery pack. An output filter is operable to reduce noise in one of the boost output and the isolated output, and the filter output of the output filter interfaces one of the boost output and the isolated output with the battery pack. An isolation bypass circuit is provided, which is operable between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter, and in the isolation connection state, the boost output is connected to the isolation input of the isolation converter. and A battery bypass circuit is provided, operable between a battery connected state and a battery disconnected state. In the battery connected state, the charging input is directly connected to the battery pack via a bypass connection between the boost converter and the isolation converter. In the battery disconnected state, this direct connection is disconnected. The isolation bypass circuit includes a relay within an isolation connection between the boost output and the filter input. The isolation bypass state occurs when the relay is in a closed state, and the isolation connection state occurs when the relay is in an open state.

15. The multifunctional vehicle battery charger module according to claim 14, wherein, The AC connection includes multiple electrical inputs and multiple switches, which are individually operable between open and closed positions to selectively connect the electrical inputs to the charging inputs depending on whether the AC connection is electrically connected to the single-phase AC charging system or the three-phase AC charging system.

16. The multifunctional vehicle battery charger module according to claim 15, wherein: The boost converter includes multiple switches and any multiple inductors arranged in a multiphase totem pole power factor correction configuration; The isolation converter includes a plurality of switches and any plurality of inductors arranged in a CLLLC converter configuration; and A pulse width modulation controller, operable to set the switching frequency and duty cycle for each of the switches of the boost converter and the isolation converter to control the boost and conversion of the charging input.

17. A multi-functional vehicle battery charger module, comprising: A boost converter, operable to boost a charging input to a boost output; An isolation converter, operable to electrically isolate the boost converter from the battery pack and to convert the boost output to an isolated output; An output filter, operable to mitigate noise within the output generated by either the boost output or the isolated output; An isolation bypass circuit is provided, which is operable between an isolation bypass state and an isolation connection state. In the isolation bypass state, the boost output is connected to the filter input of the output filter in the bypass of the isolation converter, and in the isolation connection state, the boost output is connected to the isolation input of the isolation converter. and A battery bypass circuit is operable between a connected state and a disconnected state. In the connected state, the charging input is directly connected to the output via a bypass connection between the boost converter and the isolation converter. In the disconnected state, this direct connection is broken. The isolation bypass circuit includes a relay within an isolation connection between the boost output and the filter input. The isolation bypass state occurs when the relay is in a closed state, and the isolation connection state occurs when the relay is in an open state.

18. The multifunctional vehicle battery charger module according to claim 17, wherein, The boost converter is capable of operating to generate the boost output as a high-voltage DC output when the charging input is any of the following: a lower voltage DC input below the high-voltage DC output, a single-phase AC input, or a three-phase AC input.

19. The multifunctional vehicle battery charger module according to claim 18, wherein, The boost converter is configured to generate the high-voltage DC output of 800V when the lower voltage DC input is 400V, the single-phase AC input is between 85-265V, and the three-phase AC input is between 170-265V.

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