System and method for connecting separated high voltage bus

Abstract

A vehicle includes an electrical system including a method of operating the electrical system. The electrical system includes a first set of devices configured to be connected to a power source via a primary bus, a second set of devices configured to be connected to the power source via a secondary bus, a connector device between the first set of devices and the second set of devices. The processor circulates current between the first set of devices and the second set of devices through the connector device.

Description

Technical Field

[0001] The subject disclosure relates to powering an electrical device or a group of devices, and in particular to a method of powering an electrical device that is isolated from a main power source. Background Art

[0002] An electrical system (such as the electrical system of a vehicle) may have a charging device (such as an onboard charging module) and an electrical component (such as an auxiliary power module). The onboard charging module may be connected to a power source (i.e., a battery) via a first bus, and the electrical component may be connected to the power source via a second bus. When the power source is removed or unavailable, the electrical component cannot be operated. Therefore, it is desirable to provide a system and method for powering electrical components of a vehicle without accessing the power source of the vehicle. Summary of the invention

[0003] In one exemplary embodiment, a method of operating an electrical system. A first set of devices of the electrical system is connected to a second set of devices of the electrical system via a connector device, wherein the first set of devices is connectable to a power source via a primary bus and the second set of devices is connectable to the power source via a secondary bus. Current circulates between the first set of devices and the second set of devices through the connector device.

[0004] In addition to one or more features described herein, the connector device includes at least one of a diode, a contactor, and a solid state relay.

[0005] In addition to one or more features described herein, connecting a first group of devices to a second group of devices via a connector device also includes connecting a positive terminal of the first group of devices to a positive terminal of the second group of devices via the first connector device, and connecting a negative terminal of the first group of devices to a negative terminal of the second group of devices via the second connector device.

[0006] In addition to one or more features described herein, the method also includes circulating current through one of the first connector device but not the second connector device, the second connector device but not the first connector device, and both the first connector device and the second connector device.

[0007] In addition to one or more features described herein, the first group of devices includes an on-board charging module of the vehicle, and the second group of devices is an auxiliary power module of the vehicle, further including circulating current to provide power from the on-board charging module to the auxiliary power module when the on-board charging module and the auxiliary power module are isolated from a power source.

[0008] In addition to one or more features described herein, the method also includes heating the power source via a second set of devices.

[0009] In addition to one or more features described herein, the method also includes diagnosing the electrical system by comparing a first voltage across the first group of devices with a second voltage across the second group of devices when one of the first group of devices is powered by the power supply and the connector device is forward biased to connect a second group of devices to the power supply and the second group of devices is powered by the power supply and the first group of devices is isolated from the power supply.

[0010] In another exemplary embodiment, an electrical system for a vehicle is disclosed. The electrical system includes a first group of devices configured to connect to a power source via a primary bus, a second group of devices configured to connect to the power source via a secondary bus, a connector device between the first group of devices and the second group of devices, and a processor configured to circulate current between the first group of devices and the second group of devices through the connector device.

[0011] In addition to one or more features described herein, the connector device includes at least one of a diode, a contactor, and a solid state relay.

[0012] In addition to one or more features described herein, the connector device also includes a first connector device and a second connector device, and the processor is also configured to connect the positive terminal of the first group of devices to the positive terminal of the second group of devices via the first connector device, and to connect the negative terminal of the first group of devices to the negative terminal of the second group of devices via the second connector device.

[0013] In addition to one or more features described herein, the processor is configured to circulate current through one of: the first connector device but not the second connector device, the second connector device but not the first connector device, and both the first connector device and the second connector device.

[0014] In addition to one or more features described herein, the first group of devices includes an on-board charging module, the second group of devices is an auxiliary power module, and the processor is further configured to circulate current to provide power from the on-board charging module to the auxiliary power module when the on-board charging module and the auxiliary power module are isolated from a power source.

[0015] In addition to one or more of the features described herein, the second group of devices is configured as a heating power source.

[0016] In addition to one or more features described herein, the processor is configured to diagnose the electrical system by comparing a first voltage across the first group of devices to a second voltage across the second group of devices when one of the first group of devices is powered by a power source and the connector device is forward biased to connect the second group of devices to the power source and the second group of devices is powered by the power source and the first group of devices is isolated from the power source.

[0017] In yet another exemplary embodiment, a vehicle is disclosed. The vehicle includes a power source, a first group of devices configured to connect to the power source via a primary bus, a second group of devices configured to connect to the power source via a secondary bus, a connector device between the first group of devices and the second group of devices, and a processor configured to circulate current between the first group of devices and the second group of devices through the connector device.

[0018] In addition to one or more features described herein, the connector device includes at least one of a diode, a contactor, and a solid state relay.

[0019] In addition to one or more features described herein, the connector device also includes a first connector device and a second connector device, and the processor is also configured to connect the positive terminal of the first group of devices to the positive terminal of the second group of devices via the first connector device, and to connect the negative terminal of the first group of devices to the negative terminal of the second group of devices via the second connector device.

[0020] In addition to one or more features described herein, the processor is configured to circulate current through one of: the first connector device but not the second connector device, the second connector device but not the first connector device, and both the first connector device and the second connector device.

[0021] In addition to one or more features described herein, the first group of devices includes an on-board charging module, the second group of devices is an auxiliary power module, and the processor is further configured to circulate current to provide power from the on-board charging module to the auxiliary power module when the on-board charging module and the auxiliary power module are isolated from a power source.

[0022] In addition to one or more of the features described herein, the second group of devices is configured as a heating power source.

[0023] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1 A vehicle according to an exemplary embodiment is shown;

[0026] Figure 2 A circuit diagram showing an electrical system of a vehicle in an exemplary embodiment;

[0027] Figure 3 A circuit diagram showing an electrical system in a first embodiment;

[0028] Figure 4 is a circuit diagram depicting the electrical system in a first mode of operation;

[0029] Figure 5 is a circuit diagram depicting the electrical system in a second mode of operation;

[0030] Figure 6 is a circuit diagram depicting the electrical system in a third mode of operation;

[0031] Figure 7 is a circuit diagram depicting the electrical system in a fourth mode of operation;

[0032] Figure 8 is a circuit diagram depicting an electrical system in a first fault operating mode;

[0033] Fig. 9 is a circuit diagram depicting an electrical system in a second fault operating mode;

[0034] Fig.10 A flow chart illustrating a first method for diagnosing a contactor device of an electrical system; and

[0035] Fig.11 A flow chart showing a second method for diagnosing a contactor device of an electrical system. DETAILED DESCRIPTION

[0036] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0037] According to an exemplary embodiment, Figure 1 A vehicle 10 is shown including a body 12 that at least partially defines an occupant compartment 14. The body 12 also supports various vehicle subsystems, including a propulsion system 16, and other subsystems such as braking subsystems, suspension systems, steering subsystems, etc., for supporting the functions of the propulsion system 16 and other vehicle components.

[0038] The vehicle 10 may be an electric vehicle (EV), a hybrid vehicle, or any other vehicle. In one embodiment, the vehicle 10 is an electric vehicle including a plurality of motors and / or drive systems. Any number of drive units may be included, such as one or more drive units for applying torque to the front wheels (not shown) and / or rear wheels (not shown). The drive units are controllable to operate the vehicle 10 in various operating modes, such as a normal mode, a high-performance mode (in which additional torque is applied), all-wheel drive ("AWD"), front-wheel drive ("FWD"), rear-wheel drive ("RWD"), etc.

[0039] For example, the propulsion system 16 is a multi-drive system that includes a front drive unit 20 for driving the front wheels and a rear drive unit for driving the rear wheels. The front drive unit 20 includes a front electric motor 22 and a front inverter 24 (e.g., a front power inverter module or FPIM), as well as other components such as a cooling system. The left rear drive unit 30L includes an electric motor 32L and an inverter 34L. The right rear drive unit 30R includes an electric motor 32R and an inverter 34R. Inverters 24, 34L and 34R (e.g., power inverter units or PIMs) each convert direct current (DC) power from a high voltage (HV) battery system 40 into multi-phase (e.g., two-phase, three-phase, six-phase, etc.) alternating current (AC) power to drive the front electric motor 22 and the rear electric motors 32L and 32R.

[0040] like Figure 1 As shown, the drive system features a single electric motor. However, embodiments are not limited thereto. For example, instead of a single motor, multiple drives may be provided by a single machine having physically separate sets of windings.

[0041] Also like Figure 1 As shown, the drive system is configured such that the front electric motor 22 drives the front wheels (not shown), and the rear electric motors 32L and 32R drive the rear wheels (not shown). However, embodiments are not limited in this regard, as there may be any number of drive systems and / or motors at various locations (e.g., a motor driving each wheel, dual motors per axle, etc.). Additionally, embodiments are not limited to dual drive systems, as embodiments may be used with vehicles having any number of motors and / or power inverters.

[0042] In the propulsion system 16, the front drive unit 20, the left rear drive unit 30L, and the right rear drive unit 30R are electrically connected to a battery system 40. The battery system 40 may also be electrically connected to other electrical components (also referred to as "electrical loads"), such as vehicle electronics (e.g., via an auxiliary power module or APM 42), heaters, cooling systems, etc. The battery system 40 may be configured as a rechargeable energy storage system (RESS).

[0043] In one embodiment, the battery system 40 includes a plurality of individual battery assemblies, each of which can be independently charged and can be used to independently power one or more drive systems. For example, the battery system 40 includes a first battery assembly, such as a first battery subgroup 44 connected to the front inverter 24, and a second battery subgroup 46. The first battery subgroup 44 includes a plurality of battery modules 48, and the second battery subgroup 46 includes a plurality of battery modules 50. Each battery module 48, 50 includes a plurality of individual battery cells (not shown). In various embodiments, one or more battery packs may include MODACS (Multi-Output Dynamically Adjustable Capacity) batteries, as described herein with respect to Figure 2-4 described.

[0044] Each of the front electric motor 22 and the rear electric motors 32L and 32R is a three-phase motor having a three-phase motor winding. However, the embodiments described herein are not limited thereto. For example, the motor may be any multi-phase machine supplied by a multi-phase inverter, and the drive unit may be implemented using a single machine having independent sets of windings.

[0045] The battery system 40 and / or the propulsion system 16 include a switch system having various switch devices for controlling the operation of the battery packs 44 and 46 and selectively connecting the battery packs 44 and 46 to the front drive unit 20, the left rear drive unit 30L, and the right rear drive unit 30R. The switch device can also be operated to selectively connect the first battery subgroup 44 and the second battery subgroup 46 to a charging system. The charging system can be used to charge the first battery subgroup 44 and the second battery subgroup 46, and / or supply power from the first battery subgroup 44 and / or the second battery subgroup 46 to charge another energy storage system (e.g., vehicle-to-vehicle (V2V) and / or vehicle-to-everything (V2X) charging). The charging system includes one or more charging modules. For example, a first onboard charging module (OBCM) 52 is electrically connected to a charging port 54 for charging and charging from an AC system or device (such as a utility AC power source). A second OBCM 53 may be included for DC charging (e.g., DC fast charging or DCFC). As Figure 1 As shown, the utility AC power source is a charging station 110 connected to the charging port 54 via an electrical line 112 .

[0046] In one embodiment, the switch system includes a first switch device 60 and a second switch device 62, wherein the first switch device 60 selectively connects the first battery subgroup 44 to the inverters 24, 34L and 34R, and the second switch device 62 selectively connects the second battery subgroup 46 to the inverters 24, 34L and 34R. The switch system also includes a third switch device 64 (also referred to as a "battery switch device") for selectively connecting the first battery subgroup 44 to the second battery subgroup 46 in series.

[0047] Any of a variety of controllers may be used to control the functions of the battery system 40, the switch system, and the drive unit. The controller includes any suitable processing device or unit, and an existing controller such as a drive system controller, a RESS controller, and / or a controller in a drive system may be used. For example, a controller 65 may be included to control the switch and drive control operations as discussed herein.

[0048] The controller 65 may include processing circuitry that may include an application specific integrated circuit (ASIC), electronic circuitry, a processor (shared, dedicated, or grouped) executing one or more software or firmware programs and memory, combinatorial logic circuitry, and / or other suitable components that provide the described functionality. The controller 65 may include a non-transitory computer-readable medium storing instructions that, when processed by one or more processors of the controller 65, implement a method of charging a battery according to one or more embodiments detailed herein. This method includes operating various control blocks and switches of the vehicle, as discussed herein.

[0049] The method disclosed herein is discussed for operating a vehicle. However, the method is not meant to be limited to a vehicle. In various embodiments, the method can be used to operate any suitable electrical system.

[0050] Figure 2 A circuit diagram of an electrical system 200 of a vehicle 10 in an exemplary embodiment is shown. The electrical system 200 includes a power source 202, a first group of devices 204, and a second group of devices 206. The power source 202 may be a voltage source, a battery, a battery pack, a group of batteries, etc. The first group of devices 204 may include electrical components such as an onboard charging module, an inverter for a motor, a high voltage heater, a high voltage air conditioner, etc. The second group of devices 206 may include an auxiliary power module and other electrical components.

[0051] The power source 202 is connected to the first group of devices 204 via a main bus including a main positive bus 210 and a main negative bus 212. The main positive bus 210 connects the positive terminal of the power source 202 to the positive terminal of the first group of devices 204 and includes a first main loop switch 214. The main negative bus 212 connects the negative terminal of the power source 202 to the negative terminal of the first group of devices 204 and includes a second main loop switch 216.

[0052] Similarly, the power supply 202 is connected to the second group of devices 206 via a secondary bus including a secondary positive bus 220 and a secondary negative bus 222. The secondary positive bus 220 connects the positive terminal of the power supply 202 to the positive terminal of the second group of devices 206 and includes a first secondary loop switch 224. The secondary negative bus 222 connects the negative terminal of the power supply 202 to the negative terminal of the second group of devices 206 and includes a second secondary loop switch 226.

[0053] The first auxiliary branch 228 connects the positive terminal of the first group of devices 204 to the positive terminal of the second group of devices 206. The first auxiliary branch 228 includes a first connector device 230 between the first group of devices 204 and the second group of devices 206.

[0054] Similarly, the second auxiliary branch 232 connects the negative terminal of the first group of devices 204 to the negative terminal of the second group of devices 206. The second auxiliary branch 232 includes a second connector device 234 between the first group of devices 204 and the second group of devices 206.

[0055] Figure 3 A circuit diagram 300 of the electrical system 200 in a first embodiment is shown. The first connector device is a first diode 302 that controls current flow in a direction from the positive terminal of the first group of devices 204 to the positive terminal of the second group of devices 206. The second connector device is a second diode 304 that controls current flow in a direction from the negative terminal of the second group of devices 206 to the negative terminal of the first group of devices 204. In alternative embodiments, the connector devices may be switches, contactors, solid-state relays, etc.

[0056] Figure 4 4 is a circuit diagram 400 depicting the electrical system 200 in a first operating mode. The first operating mode is a normal (functional) operating mode. The first main circuit switch 214 and the second main circuit switch 216 are disconnected, and the first secondary circuit switch 224 and the second secondary circuit switch 226 are disconnected. Therefore, the main current loop is not established (i.e., the first group of devices 204 are isolated from the power supply 202) and the secondary circuit is not established (i.e., the second group of devices 206 are isolated from the power supply). However, the voltage difference across the first group of devices 204 forward biases the first diode 302 and the second diode 304, thereby creating a free current loop 402 through the first diode, the secondary group device 206 and the second diode to power the secondary group device 206. Since the first group of devices 204 includes the on-board control module 52, 53, and the second group of devices 206 includes the auxiliary power module 42, the on-board control module can provide power to the auxiliary power module. In one embodiment, the secondary group device 206 can include an electric pump that can pump coolant through the power supply 202 to heat the power supply 202. In a cold environment, the power supply 202 may be at a temperature at which it cannot operate. By operating the pump via the free current loop 402, the temperature of the power supply 202 may be raised to a temperature at which it can operate. The pump may be powered by the auxiliary power module 42. At least one of the first group of devices 204 and the second group of devices 206 may include an electric heater for heating the coolant so that the coolant can also raise the temperature of the power supply 202.

[0057] Figure 55 is a circuit diagram 500 depicting the electrical system 200 in the second operating mode. The second operating mode is a normal operating mode. A main current loop 502 is established (i.e., the first main loop switch 214 and the second main loop switch 216 are closed), and a secondary current loop 504 is established (i.e., the first secondary loop switch 224 and the second secondary loop switch 226 are closed). In this mode, there is no voltage difference, and therefore no forward bias across the first diode 302. Therefore, no current flows through the first diode 302 and the first auxiliary branch 228 can be considered as removed from the circuit. Similarly, there is no voltage difference, and therefore no forward bias across the second diode 304. Therefore, no current flows through the second diode 304, and the second auxiliary branch 232 can be considered as removed from the circuit.

[0058] Figure 6 6 is a circuit diagram 600 depicting the electrical system 200 in a third operating mode. The third operating mode is for powering the second group of devices 206 (and thus the auxiliary power module) via the power source 202. The first main circuit switch 214 and the second main circuit switch 216 are open. Therefore, the main circuit 502 is not established ( Figure 5 ). The first secondary loop switch 224 and the second secondary loop switch 226 are closed, thereby allowing current to flow through the secondary current loop 504.

[0059] Figure 7 700 is a circuit diagram depicting the electrical system 200 in a fourth operating mode. The fourth operating mode can be used to reduce contactor cycles in the first connector device (e.g., the first diode 302) and the second connector device (e.g., the second diode 304). The first main circuit switch 214 and the second main circuit switch 216 are closed, thereby allowing current to flow through the main current circuit 502. The first secondary circuit switch 224 and the second secondary circuit switch 226 are open. Therefore, no current flows through the secondary current circuit 504 ( Figure 6 Due to the configuration of the switches, a voltage difference exists across the first diode 302 and the second diode 304, thereby forward biasing the diodes and allowing a current 402 to flow through the first auxiliary branch 228 and the second auxiliary branch 232, respectively.

[0060] Figure 8 800 is a circuit diagram depicting the electrical system 200 in a first fault operation mode. The first main loop switch 214 and the second main loop switch 216 are closed, thereby allowing the first auxiliary current 802 to flow through the main current loop 502. The first secondary loop switch 224 is open due to the fault, and the second secondary loop switch 226 is closed. Therefore, the secondary current loop is not established. However, the first auxiliary current 802 can flow through the first diode 302, the second group of devices 206, and the second secondary loop switch 226 to power the second group of devices.

[0061] Fig. 9 900 is a circuit diagram depicting the electrical system 200 in a second fault operating mode. The first main circuit switch 214 and the second main circuit switch 216 are closed, thereby allowing current to flow through the main current circuit 502. The first secondary circuit switch 224 is closed, while the second secondary circuit switch 226 is open due to the fault. Therefore, no current flows through the secondary current circuit 504 ( Figure 6 ). However, the second auxiliary current 902 may flow through the first secondary loop switch 224, the second group of devices 206, and the second diode 304 to power the second group of devices.

[0062] Fig.10 A flow chart 1000 of a first method for diagnosing a contactor device of an electrical system 200 is shown. The method begins at block 1002, where the primary circuit switch and the secondary circuit switch are in an open position. In block 1004, the primary voltage circuit is energized (closing the first primary circuit switch 214 and the second primary circuit switch 216), while the secondary voltage circuit is disconnected from the power source 202. In block 1006, a first voltage across the primary voltage circuit is compared to a second voltage across the secondary voltage circuit. If the first voltage is equal to the second voltage within a selected threshold, the method proceeds to block 1008. Otherwise, the method proceeds to block 1010.

[0063] In box 1008, a signal is generated to indicate that the electrical system passed the diagnostic test. The method then proceeds to box 1014, where the method ends. In box 1010, a signal is generated to indicate that the electrical system failed the diagnostic test. In box 1012, appropriate remedial action is taken. In box 1014, the method ends.

[0064] Fig.11 A flow chart 1100 of a second method for diagnosing a contactor device of an electrical system 200 is shown. The method begins at box 1102, where the primary circuit switch and the secondary circuit switch are in the open position. In box 11004, the secondary voltage circuit is energized (closing the first secondary circuit switch 224 and the second secondary circuit switch 226), while the first voltage circuit is disconnected from the power source 202. In box 1106, a first voltage across the primary voltage circuit is compared to a second voltage across the secondary voltage circuit. If the first voltage is equal to the second voltage within a selected threshold, the method proceeds to box 1108. Otherwise, the method proceeds to box 1110.

[0065] In box 1108, a signal is generated to indicate that the electrical system has passed the diagnostic test. The method then proceeds to box 1114, where the method ends. In box 1110, a signal is generated to indicate that the electrical system has not passed the diagnostic test. In box 1112, appropriate remedial action is taken. In box 1014, the method ends.

[0066] The terms "a" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0067] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0068] Unless stated to the contrary herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0069] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0070] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A method of operating an electrical system, comprising: connecting a first group of devices of the electrical system to a second group of devices of the electrical system via a connector device, wherein the first group of devices is connectable to a power source via a primary bus and the second group of devices is connectable to the power source via a secondary bus; as well as Current is circulated between the first group of devices and the second group of devices through the connector device.

2. The method of claim 1, wherein the connector device comprises at least one of: (i) a diode; (ii) a contactor; and (iii) a solid state relay.

3. The method of claim 1 , wherein connecting the first group of devices to the second group of devices via the connector device further comprises connecting a positive terminal of the first group of devices to a positive terminal of the second group of devices via the first connector device, and connecting a negative terminal of the first group of devices to a negative terminal of the second group of devices via the second connector device.

4. The method of claim 1 , wherein the first group of devices comprises an on-board charging module of a vehicle and the second group of devices is an auxiliary power module of the vehicle, the method further comprising circulating the current to provide power from the on-board charging module to the auxiliary power module when the on-board charging module and the auxiliary power module are isolated from the power source.

5. The method of claim 1, further comprising heating the power source via a second set of devices.

6. An electrical system for a vehicle, comprising: a first set of devices configured to be connected to a power source via a main bus; a second set of devices configured to be connected to the power supply via a secondary bus; a connector device between the first set of devices and the second set of devices; as well as A processor is configured to circulate current between the first group of devices and the second group of devices through the connector device.

7. The electrical system of claim 6, wherein the connector device comprises at least one of: (i) a diode; (ii) a contactor; and (iii) a solid state relay.

8. An electrical system according to claim 6, wherein the connector device further comprises a first connector device and a second connector device, and the processor is further configured to connect the positive terminal of the first group of devices to the positive terminal of the second group of devices via the first connector device, and to connect the negative terminal of the first group of devices to the negative terminal of the second group of devices via the second connector device.

9. The electrical system of claim 6, wherein the first group of devices comprises an on-board charging module, the second group of devices is an auxiliary power module, and the processor is further configured to circulate the current to provide power from the on-board charging module to the auxiliary power module when the on-board charging module and the auxiliary power module are isolated from the power source.

10. The electrical system of claim 6, wherein the second set of devices is configured to heat the power source.

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