Dark start power supply calibration and optimizer

Abstract

The invention provides a dark start power supply calibration and optimizer. A bi-directional energy transfer system for transferring energy between a motorized vehicle and other structures is provided. A bi-directional energy transfer system may utilize dark start reserve power from a dark start energy storage resource to maintain communication between electric vehicle supply equipment (EVSE) and a combiner box during a grid outage condition. The output voltage of the dark start energy storage resource may be boosted within a variable voltage regulation boost circuit of the combiner box in order to supply the calibrated output voltage to the EVSE. The calibrated output voltage compensates for a voltage drop that may occur across the length of the cable extending between the EVSE and the combiner box.

Description

Technical Field

[0001] The present disclosure generally relates to a bidirectional energy transfer system capable of transferring energy between an electrified vehicle and other structures. Background Art

[0002] Plug-in electric vehicles include one or more charging ports for charging the traction battery pack. Plug-in vehicles are typically charged while parked at a charging station or some other utility power source. Plug-in vehicles can also be used to support household loads during power outages. Summary of the Invention

[0003] A bidirectional energy transfer system according to an exemplary aspect of the present disclosure includes, among other things, electric vehicle supply equipment (EVSE) and a combiner box, wherein the combiner box includes a dark-start energy storage resource and a variable voltage-regulating boost circuit, wherein the variable voltage-regulating boost circuit is configured to increase the output voltage of the dark-start energy storage resource for powering circuits of the EVSE during a grid blackout condition.

[0004] In further non-limiting embodiments of the foregoing bidirectional energy transfer system, the dark start energy storage resource is a battery, a capacitor, or a supercapacitor.

[0005] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the variable voltage regulating boost circuit is configured to boost the output voltage to compensate for voltage drops that may occur across a length of a cable extending from the EVSE to the combiner box.

[0006] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the cable is a Power over Ethernet (PoE) cable.

[0007] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, a control system is programmed to control the variable voltage regulating boost circuit for increasing the output voltage during the grid outage condition.

[0008] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the control system includes a first control module of the combiner box and a second control module of the EVSE.

[0009] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the second control module is programmed to determine the voltage drop based on a comparison between a measured output voltage received from the variable voltage regulating boost circuit and a calibrated output voltage setting received from the first control module.

[0010] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the first control module is programmed to determine a calibrated output voltage for powering the circuit based on the voltage drop.

[0011] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the first control module is programmed to command the variable voltage regulating boost circuit to adjust the output voltage to the calibrated output voltage for powering the circuit.

[0012] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the EVSE includes a dark start measurement circuit configured to measure the output voltage.

[0013] In a further non-limiting embodiment of any of the foregoing bidirectional energy transfer systems, the EVSE further includes a filter and a switch mode power supply (SMPS).

[0014] A method according to another exemplary aspect of the present disclosure includes, among other things, boosting an output voltage of a dark start energy storage resource of a combiner box during a grid outage condition, and using the boosted output voltage to power communications between electric vehicle supply equipment (EVSE) and an electrified vehicle.

[0015] In a further non-limiting embodiment of the foregoing method, the combiner box includes a variable voltage regulating boost circuit configured to boost the output voltage.

[0016] In a further non-limiting embodiment of any of the foregoing methods, boosting the output voltage includes sending a calibrated output voltage setting and a first output voltage from the combiner box to the EVSE.

[0017] In further non-limiting embodiments of any of the foregoing methods, boosting the output voltage further comprises measuring the first output voltage within a dark start measurement circuit of the EVSE to determine a measured output voltage received by the EVSE.

[0018] In a further non-limiting embodiment of any of the foregoing methods, boosting the output voltage includes comparing the measured output voltage to a calibrated output voltage setting and determining a voltage drop.

[0019] In a further non-limiting embodiment of any of the foregoing methods, boosting the output voltage includes sending a voltage drop to a combiner box.

[0020] In a further non-limiting embodiment of any of the foregoing methods, boosting the output voltage includes adjusting the first output voltage to a second output voltage derived from a voltage drop.

[0021] In further non-limiting embodiments of any of the foregoing methods, the second output voltage is the sum of the voltage drop plus a minimum required voltage output necessary to maintain proper control pilot operation between the EVSE and the electrified vehicle.

[0022] In a further non-limiting embodiment of any of the foregoing methods, in response to establishing the communication between the EVSE and the electrified vehicle, the method includes transferring power from the electrified vehicle to a structure separate from the electrified vehicle during the grid outage condition.

[0023] The embodiments, examples and alternatives of the preceding paragraphs, claims or following description and drawings (including any of their various aspects or corresponding individual features) may be taken independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible.

[0024] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description.The drawings that accompany the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A first configuration of a bidirectional energy transfer system is schematically shown.

[0026] Figure 2 Schematically shows Figure 1 A second configuration of the bidirectional energy transfer system.

[0027] Figure 3 Schematically shows Figure 1 and Figure 2 Additional aspects of the bidirectional energy transfer system.

[0028] Figure 4 is a flow chart of an exemplary method for controlling a bidirectional energy transfer system during a grid outage condition. DETAILED DESCRIPTION

[0029] The present disclosure relates to a bidirectional energy transfer system capable of transferring energy between an electrified vehicle and other structures. The bidirectional energy transfer system can utilize dark start reserve power from a dark start energy storage resource to maintain communication between an electric vehicle supply equipment (EVSE) and a combiner box during a grid outage condition. The output voltage of the dark start energy storage resource can be increased within a variable voltage regulating boost circuit of the combiner box to supply a calibrated output voltage to the EVSE. The calibrated output voltage compensates for the voltage drop that may occur across the length of the cable extending between the EVSE and the combiner box. These and other features of the present disclosure are discussed in more detail in the following paragraphs of this detailed description.

[0030] Figure 1 、 Figure 2 and Figure 3 An exemplary bidirectional energy transfer system 10 (hereinafter referred to as "system 10") for bidirectionally transferring energy between a vehicle 12 and a structure 14 is schematically illustrated. System 10 enables bidirectional energy transfer from vehicle 12 to structure 14, or vice versa. Structure 14 may be a residential building, a commercial building, a parking lot, a charging station, or any other type of structure capable of receiving or transferring energy. In one embodiment, structure 14 is a residential residence that serves as a "home location" for vehicle 12.

[0031] Although specific component relationships are shown in the drawings of this disclosure, the illustrations are not intended to limit this disclosure. The arrangement and orientation of the various components of the depicted systems are shown schematically and may vary within the scope of this disclosure. In addition, the various drawings accompanying this disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to emphasize certain details of a particular component, assembly, or system.

[0032] In one embodiment, vehicle 12 is a plug-in electric vehicle (e.g., a plug-in hybrid electric vehicle (PHEV) or a battery electric vehicle (BEV). Vehicle 12 includes a traction battery pack 16 that is part of an electrified powertrain capable of applying torque from an electric machine (e.g., an electric motor) to drive wheels 18 of vehicle 12. The electrified powertrain of vehicle 12 can electrically propel the set of wheels 18 with or without assistance from an internal combustion engine.

[0033] Figures 1 to 2 The vehicle 12 is schematically shown as a sedan. However, other vehicle configurations are also contemplated. The teachings of the present disclosure can be applied to any type of vehicle, such as the vehicle 12. For example, the vehicle 12 can be configured as a sedan, a pickup truck, a van, a sport utility vehicle (SUV), etc.

[0034] Although shown schematically, the traction battery pack 16 may be configured as a high-voltage traction battery pack that includes a plurality of battery arrays 20 (e.g., battery assemblies or groups of battery cells) capable of outputting electrical power to one or more electric machines of the vehicle 12. Other types of energy storage devices and / or output devices may also be used to power the vehicle 12.

[0035] The vehicle 12 can interface with the structure 14 via electric vehicle supply equipment (EVSE) 22 to perform bidirectional energy transfer of the system 10. In one embodiment, the EVSE 22 is a wall box that can be mounted to a wall 25 of the structure 14. A charging cable 24 can operably connect the EVSE 22 to a charging port assembly 26 of the vehicle 12 for transferring energy between the vehicle 12 and the structure 14. The charging cable 24 can be configured to provide any level of charging (e.g., 120VAC, 240VAC, direct current (DC) charging, etc.).

[0036] The EVSE 22 can be operably connected to the AC infrastructure 30 of the structure 14 through a home energy management system 28. The home energy management system 28 can include a combiner box 40, which is a type of bidirectional energy transfer module. For example, various electrical loads 31, such as household appliance loads, can be associated with the AC infrastructure 30. Electrical loads 31 are sometimes referred to as transient loads of the AC infrastructure 30 and can include loads associated with common kitchen appliances, washers, dryers, water heaters, air conditioning units, furnaces, home alarm systems, sump pump systems, routers, home lighting systems, and the like. The AC infrastructure 30 can also include a main service panel 33, which is operably positioned between the combiner box 40 and the electrical loads 31.

[0037] Power from a grid power source 32 (e.g., an AC power source), power from a renewable power source 34 (e.g., solar, wind, etc.), power from the vehicle 12, or some combination thereof can be selectively delivered to the AC infrastructure 30 for use in powering the electrical loads 31. A combiner box 40 can control the delivery of power to the AC infrastructure 30. In some embodiments, the combiner box 40 can further control the delivery of power to the grid power source 32. For example, power from the vehicle 12 can be periodically delivered back to the grid power source 32 through the combiner box 40.

[0038] The combiner box 40 can serve as a junction between the AC infrastructure 30 and each of the grid power source 32, the vehicle 12, and the renewable power source 34. The combiner box 40 can electrically isolate the AC infrastructure 30 from the grid power source 32 during a grid outage condition and can control the turning on and off of the electrical loads 31. In one embodiment, the combiner box 40 can activate a transfer switch to separate the grid power source 32 from the electrical loads 31, and then pass power from the renewable power source 34, the vehicle 12, or both to the electrical loads 31.

[0039] Power received from or delivered to the vehicle 12 may be transferred through the combiner box 40. The combiner box 40 is configured to facilitate bidirectional power transfer between the vehicle 12 and the structure 14. The home energy management system 28 may include various equipment necessary to enable power transfer to / from the vehicle 12.

[0040] The vehicle 12 may also include a vehicle power transfer system 36 configured to further enable bidirectional power transfer between the vehicle 12 and the structure 14. The vehicle power transfer system 36 may be operably connected between the charge port assembly 26 and the traction battery pack 16 of the vehicle 12. The vehicle power transfer system 36 may include various equipment for enabling the vehicle 12 to serve as a backup power source for delivering power to the structure 14, such as a charger, a converter, an inverter, HV relays or contactors, a motor controller (which may be referred to as an inverter system controller or ISC), etc. The vehicle power transfer system 36 may also be configured to enable the vehicle 12 to receive power from the structure 14 and to transfer energy between the traction battery pack 16 and one or more electric motors of the vehicle 12.

[0041] A non-limiting example of a suitable vehicle power transfer system that may be employed within the vehicle 12 to implement bidirectional power transfer is disclosed in U.S. Patent Publication No. 2020 / 0324665, assigned to Ford Global Technologies LLC, the disclosure of which is incorporated herein by reference. However, other power transfer systems may be utilized to implement bidirectional power transfer within the scope of the present disclosure.

[0042] Figure 1 A first configuration C1 of the system 10 is schematically illustrated. During the first configuration C1, electrical power may be transferred from the structure 14 to the vehicle 12, such as for charging the traction battery pack 16 of the vehicle 12. The direction of energy transfer during the first configuration C1 is schematically depicted by arrows 38.

[0043] Figure 2A second configuration C2 of the system 10 is schematically illustrated. During the second configuration C2, electrical power can be transferred from the traction battery pack 16 of the vehicle 12 to the structure 14. The direction of energy transfer during the second configuration C2 is schematically illustrated by arrows 39. In this manner, the vehicle 12 can be employed as a backup energy management system, such as to power the electrical loads 31 of the structure 14 when electrical power from the grid power source 32 is temporarily unavailable, for example due to a power outage.

[0044] The EVSE 22 can be configured to communicate with both the vehicle 12 and the combiner box 40 to facilitate the transfer of power from the vehicle 12 to the structure 14 for powering the electrical loads 31 of the AC infrastructure 30. When power is transferred from the vehicle 12, the EVSE 22 is operably coupled to the vehicle 12. The EVSE 22 is operably coupled to the structure 14 through the combiner box 40.

[0045] It will be appreciated that the EVSE 22 and the combiner box 40 are typically powered by the grid power source 32. However, during a grid blackout condition where energy from the grid power source 32 is temporarily unavailable, the EVSE 22 and the combiner box 40 still need to be powered in order to be able to detect the vehicle 12 and communicate with each other to transfer power from the vehicle 12 to the structure 14. This is sometimes referred to as a "dark start."

[0046] The home energy management system 28 may additionally include a dark start energy storage resource 42 operatively connected to the combiner box 40. Figures 1 to 2 4. The combiner box 40 is shown separately from the combiner box 40, but the combiner box 40 and the dark start energy storage resource 42 can be integrated together as part of a common module (see, e.g. Figure 3 ).

[0047] For example, when power is unavailable from the grid power source 32 or any other energy source (e.g., the renewable power source 34), the dark start energy storage resource 42 may be able to supply a limited amount of backup power to certain components of the system 10, such as the EVSE 22. The dark start energy storage resource 42 may include a battery (e.g., a 13V battery), a capacitor, an ultracapacitor, or any other suitable energy storage device.

[0048] Now the main reference Figure 3, the EVSE 22 may include internal circuitry 44, a filter 46, and a switch-mode power supply (SMPS) 48. The circuitry 44 may include the components necessary for the EVSE 22 to transfer energy between the vehicle 12 and the structure 14. The SMPS 48 may be a dual-mode SMPS that can receive input power from the vehicle 12 or from the grid power source 32 via the combiner box 40. During normal operating conditions of the grid power source 32, for example, power (such as 240 VAC power) may be transferred from the grid power source 32 to the filter 46 and then to the SMPS 48. The SMPS 48 may convert the 240 VAC input from the grid power source 32 into a 12 VDC output that may be used to power the circuitry 44 of the EVSE 22. Thus, the EVSE 22 and the combiner box 40 are sufficiently powered to enable communication between them and with the vehicle 12 to prepare for and initiate energy transfer between the vehicle 12 and the structure 14.

[0049] As discussed further below, the EVSE 22 and the combiner box 40 can each include features that enable the EVSE 22 and the combiner box 40 to maintain communication with each other and with the vehicle 12 even when the grid power source 32 is unable to provide power to the system 10. Notably, the features do not require the EVSE 22 to include a battery sized to power every function of the EVSE 22. Thus, in this embodiment, the EVSE 22 is considered battery-less, which can reduce the overall packaging requirements of the EVSE 22.

[0050] The combiner box 40 may include a variable voltage regulating boost circuit 50 that is operably connected to the dark start energy storage resource 42. The variable voltage regulating boost circuit 50 may be configured to selectively boost the output voltage received from the dark start energy storage resource 42. The boosted power may then be delivered to the EVSE 22 to power the circuit 44 via a cable 64 extending from the EVSE 22 to the combiner box 40. The output voltage from the dark start energy storage resource 42 may need to be boosted before being delivered to the EVSE 22 to account for voltage drops that may occur due to cable resistance across the length of the cable 64 when the distance between the EVSE 22 and the combiner box 40 is relatively large (e.g., greater than 100 feet).

[0051] In one embodiment, the cable 64 is a Power over Ethernet (PoE) cable. Thus, both power and data can be sent to the EVSE 22 via the cable 64.

[0052] The EVSE 22 may include a dark start measurement circuit 52. The dark start measurement circuit 52 may be configured to measure the boosted output voltage received from the variable voltage regulating boost circuit 50 when the dark start energy storage resource 42 is supplying backup power during a grid blackout condition. As explained further below, the output voltage measured by the dark start measurement circuit 52 may be used to determine a voltage drop across the length of the cable, which may then be used to adjust the calibrated output voltage provided by the variable voltage regulating boost circuit 50.

[0053] The control system 54 can control various functions associated with the system 10, and specifically can be programmed to control the EVSE 22 and the combiner box 40 to maintain communication during a grid outage condition and facilitate power output from the vehicle 12 to the structure 14. The control system can include at least a first control module 56 and a second control module 58. The first control module 56 can be a component of the combiner box 40, and the second control module 58 can be a component of the EVSE 22. Although two control modules are specifically shown, the system 10 can include a greater number of controllers that are operably connected and configured to function together to facilitate various control strategies associated with the system 10.

[0054] The first control module 56 and the second control module 58 can each include a processor 60 and a non-transitory memory 62 for executing various control strategies and modes associated with the system 10. The processor 60 can be a custom or commercially available processor, a central processing unit (CPU), or generally any device for executing software instructions. The memory 62 can include a combination of volatile memory elements and non-volatile memory elements. Volatile memory elements require power to store data, while non-volatile memory elements can store data without consuming power. The processor 60 can be operably coupled to the memory 62 and can be configured to execute one or more programs stored in the memory 62 based on various inputs received from other devices, such as the dark start energy storage resource 42, the variable voltage regulation boost circuit 50, the dark start measurement circuit 52, etc.

[0055] Continue to refer Figures 1 to 3 , Figure 4An exemplary method 100 for controlling the system 10 during a grid outage condition is schematically illustrated in flowchart form. Specifically, the system 10 can be controlled to efficiently use dark start reserve power from the dark start energy storage resource 42 to maintain communication between the EVSE 22 and the combiner box 40 during a grid outage condition. The system 10 can be configured to employ one or more algorithms suitable for performing at least a portion of the steps of the exemplary method 100. For example, the method 100 can be stored as executable instructions in a memory of the control system 54, and the executable instructions can be embodied in any computer-readable medium that can be executed by a processor of the control system 54.

[0056] Exemplary method 100 may begin at block 102. At block 104, method 100 may confirm whether power is available from grid power source 32. If "no," thus indicating a grid blackout condition, method 100 may proceed to block 106 by determining whether power is available from renewable power source 34 or any other source. If block 106 returns a "no" response, method 100 may proceed to block 108.

[0057] At block 108, the combiner box 40 may send both the calibrated output voltage setting (data) and the first output voltage (power) from the dark start energy storage resource 42 to the EVSE 22. The calibrated output voltage setting may be a preset value (e.g., 20V) that is large enough to account for the worst-case voltage drop on the cable 64.

[0058] The dark start measurement circuit 52 of the EVSE 22 can measure the first output voltage at block 110 to determine a measured output voltage received by the EVSE 22. At block 112, the measured output voltage can be compared with a calibrated output voltage setting (e.g., such as via the second control module 58) to determine a voltage drop (data) between the EVSE 22 and the combiner box 40. In one embodiment, the voltage drop is the difference between the calibrated output voltage setting and the first output voltage. At block 114, the voltage drop information can be sent to the combiner box 40 via the cable 64.

[0059] Next, at block 116, the variable voltage regulating boost circuit 50 (e.g., such as via a command from the first control module 56) may adjust the output voltage from the dark start energy storage resource 42 to a second output voltage based on the voltage drop. In one embodiment, the second output voltage is calculated by adding the voltage drop value to the minimum required voltage output necessary to maintain proper control pilot operation between the EVSE 22 and the vehicle 12. In one embodiment, the minimum required voltage output is 12V.

[0060] Since dark start energy has been used to maintain communication between the EVSE 22 and the combiner box 40, the method 100 may then proceed to block 118 and prepare the system 10 to transfer energy from the vehicle 12 to the structure 14. The vehicle 12 may then transfer energy to return power to the structure 14 at block 120. The method 100 may end at block 122.

[0061] The bidirectional energy transfer system described herein includes a dark-start energy storage resource that can power system loads during grid blackout conditions. The output voltage of the dark-start energy storage resource can be selectively boosted by a variable voltage-regulating boost circuit to provide a calibrated output voltage to the EVSE that compensates for voltage drops. Thus, the proposed system eliminates the need for a dedicated power supply within the EVSE and can further reduce the size of the dark-start energy storage resource required to maintain system operability. Furthermore, because the output of the boost circuit is a regulated voltage source, the EVSE also eliminates the need for a secondary switch-mode power supply, further reducing components and complexity within the EVSE.

[0062] Although different non-limiting embodiments are shown as having specific components or steps, the embodiments of the present disclosure are not limited to these specific combinations. Some components or features from any one of the non-limiting embodiments can be used in combination with features or components from any one of the other non-limiting embodiments.

[0063] It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings.It should be understood that although particular component arrangements are disclosed and shown in these exemplary embodiments, other arrangements may also benefit from the teachings of this disclosure.

[0064] The foregoing description should be interpreted as illustrative and not limiting. Those skilled in the art will appreciate that certain modifications may occur within the scope of this disclosure. For these reasons, the appended claims should be studied to determine the true scope and content of this disclosure.

Claims

1. A bidirectional energy transfer system comprising: Electric vehicle supply equipment (EVSE); and A combiner box includes a dark start energy storage resource and a variable voltage regulating boost circuit configured to boost an output voltage of the dark start energy storage resource for powering circuits of the EVSE during a grid blackout condition.

2. The bidirectional energy transfer system of claim 1, wherein the dark start energy storage resource is a battery, a capacitor, or a supercapacitor.

3. A bidirectional energy transfer system as described in claim 1 or 2, wherein the variable voltage regulating boost circuit is configured to boost the output voltage to compensate for voltage drops that can occur across the length of a cable extending from the EVSE to the combiner box, and optionally wherein the cable is a Power over Ethernet (PoE) cable.

4. A bidirectional energy transfer system as claimed in any preceding claim, comprising a control system programmed to control the variable voltage regulating boost circuit for increasing the output voltage during the grid outage condition. 5 . The bidirectional energy transfer system of claim 4 , wherein the control system comprises a first control module of the combiner box and a second control module of the EVSE.

6. The bidirectional energy transfer system of claim 5, wherein the second control module is programmed to determine the voltage drop based on a comparison between a measured output voltage received from the variable voltage regulated boost circuit and a calibrated output voltage setting received from the first control module. 7 . The bidirectional energy transfer system of claim 6 , wherein the first control module is programmed to determine a calibrated output voltage for powering the circuit based on the voltage drop.

8. The bidirectional energy transfer system of claim 7, wherein the first control module is programmed to command the variable voltage regulating boost circuit to adjust the output voltage to the calibrated output voltage for powering the circuit.

9. The bidirectional energy transfer system of any preceding claim, wherein the EVSE comprises a dark start measurement circuit configured to measure the output voltage, and optionally wherein the EVSE further comprises a filter and a switch mode power supply (SMPS).

10. A method comprising: boosting the output voltage of the dark start energy storage resource of the combiner box during a grid blackout condition; as well as The boosted output voltage is used to power communications between electric vehicle supply equipment (EVSE) and the electrified vehicle. 11 . The method of claim 10 , wherein the combiner box comprises a variable voltage regulating boost circuit configured to boost the output voltage.

12. The method of claim 10 or 11, wherein increasing the output voltage comprises: A calibrated output voltage setting and a first output voltage are sent from the combiner box to the EVSE.

13. The method of claim 12 , wherein increasing the output voltage further comprises: measuring the first output voltage within a dark start measurement circuit of the EVSE to determine a measured output voltage received by the EVSE; comparing the measured output voltage to the calibrated output voltage setting; as well as Determine the voltage drop.

14. The method of claim 13 , wherein boosting the output voltage comprises: sending the voltage drop to the combiner box; as well as adjusting the first output voltage to a second output voltage derived from the voltage drop, Wherein the second output voltage is the sum of the voltage drop plus a minimum required voltage output necessary to maintain proper control pilot operation between the EVSE and the electrified vehicle.

15. The method of any one of claims 10 to 14, comprising, in response to establishing the communication between the EVSE and the electrified vehicle: Power is transferred from the electrified vehicle to a structure separate from the electrified vehicle during the grid outage condition.

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