Multifunctional vehicle-mounted charger module

Abstract

A multifunctional on-board charger module is provided. An on-board charging system for an electric vehicle includes: a charging port configured to receive alternating current (AC) power; a power socket; a direct current (DC) battery selectively coupled to the charging port via a first switch and a second switch; a bidirectional inverter selectively coupled to the battery via a third switch, a fourth switch, and a fifth switch; a motor coupled to the bidirectional inverter and selectively coupled to the charging port via a sixth switch; a DC-AC converter selectively coupled to the motor via a seventh switch and an eighth switch and selectively coupled to the power socket via a ninth switch, a tenth switch, and an eleventh switch; and a DC-DC converter coupled to the DC-AC converter and selectively coupled to the battery via a twelfth switch and a thirteenth switch, the charging port selectively coupled to the battery.

Description

Technical Field

[0001] The information provided in this section is for the purpose of presenting the general background of this disclosure. To the extent described in this section, the work of the currently named inventors, and aspects of the description that may otherwise not conform to the prior art at the time of filing, are neither explicitly nor implicitly considered to be prior art of this disclosure.

[0002] This disclosure relates generally to electric vehicles, and more specifically to on-board charging systems for electric vehicles. Background Technology

[0003] Electric vehicles use high-voltage batteries to power one or more electrical machines, thereby delivering torque to the vehicle's drivetrain, either alone or in conjunction with an internal combustion engine. The term "plug-in vehicle" describes any vehicle, such as a battery electric vehicle or a hybrid electric vehicle, for example, by plugging a charging cable from the vehicle into a 120VAC or 240VAC wall outlet.

[0004] An on-board charging module (OBCM) can be used to facilitate the recharging of high-voltage batteries. A typical OBCM has the electronic circuitry hardware and control software required to convert single-phase or three-phase alternating current (AC) grid voltage into a direct current (DC) voltage usable by the battery. Some of this electronic circuitry hardware occupies a significant amount of space and / or adds considerable weight to the vehicle. The disadvantages of existing systems will be addressed by one or more aspects of this disclosure. Summary of the Invention

[0005] An electric vehicle is provided, comprising: a charging port configured to receive alternating current (AC) power; a power outlet configured to provide AC power to one or more external devices; and a direct current (DC) battery selectively coupled to the charging port via a first switch and a second switch. The electric vehicle also includes a bidirectional inverter configured to convert AC power to DC power and DC power to AC power, the bidirectional inverter being selectively coupled to the battery via a third switch, a fourth switch, and a fifth switch. The electric vehicle further includes: a motor coupled to the bidirectional inverter and selectively coupled to the charging port via a sixth switch; a DC-AC converter selectively coupled to the motor via a seventh and eighth switch and selectively coupled to the power outlet via a ninth, tenth, and eleventh switch; and a DC-DC converter coupled to the DC-AC converter and selectively coupled to the battery via a twelfth and thirteenth switch. The charging port is selectively coupled to the bidirectional inverter, the motor, or the DC-AC converter via a fourteenth switch. The electric vehicle also includes a processor configured to control the operation of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, and fourteenth switches based on the electric vehicle's operating mode.

[0006] Electric vehicles may include one or more of the following optional aspects. For example, one or more fuses may be positioned adjacent to the positive and negative terminals of the battery.

[0007] According to at least one aspect, during the vehicle-to-vehicle DC boost mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the seventh switch, the ninth switch, the tenth switch, the eleventh switch, the twelfth switch, and the thirteenth switch in the open position, and puts the fourth switch, the fifth switch, the sixth switch, and the fourteenth switch in the closed position.

[0008] According to another aspect, during the vehicle-to-vehicle buck mode of the electric vehicle, the processor puts the first, second, third, fourth, fifth, ninth, tenth, and eleventh switches in the open position and puts the sixth, seventh, eighth, twelfth, thirteenth, and fourteenth switches in the closed position.

[0009] According to at least one example, during the vehicle-to-load inverter module mode of an electric vehicle, the processor puts the first, second, third, fourth, fifth, sixth, seventh, eighth, and fourteenth switches in the open position and puts the ninth, tenth, eleventh, twelfth, and thirteenth switches in the closed position.

[0010] According to another example, during the vehicle-to-grid mode of an electric vehicle, the processor puts the first, second, third, fourth, fifth, ninth, tenth, and eleventh switches in the open position and the sixth, seventh, eighth, twelfth, thirteenth, and fourteenth switches in the closed position.

[0011] According to at least one aspect, during the vehicle-to-home mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch, and the eleventh switch in the off position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch, and the fourteenth switch in the closed position.

[0012] According to another aspect, during the AC charging mode of the electric vehicle, the processor puts the third, fourth, fifth, ninth, tenth, eleventh, first, and second switches in the off position, and puts the twelfth, thirteenth, fourteenth, sixth, seventh, and eighth switches in the closed position.

[0013] According to at least one example, during the propulsion mode of an electric vehicle, the processor puts the first, second, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, and fourteenth switches in the off position, and first closes the third and fifth switches to precharge the inverter capacitor, and then opens the third switch and closes the fourth switch.

[0014] According to another example, during the DC fast charging mode of the electric vehicle, the processor puts the third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth and fourteenth switches in the off position, and puts the first and second switches in the closed position.

[0015] In another configuration, an on-board charging system for an electric vehicle is provided, comprising: a charging port configured to receive alternating current (AC) power; a power outlet configured to provide AC power to one or more external devices; and a direct current (DC) battery selectively coupled to the charging port via a first switch and a second switch. The on-board charging system further comprises: a bidirectional inverter configured to convert AC power to DC power and DC power to AC power, the bidirectional inverter being selectively coupled to the battery via a third switch, a fourth switch, and a fifth switch; and an electric motor coupled to the bidirectional inverter and selectively coupled to the charging port via a sixth switch. The on-board charging system further comprises: a DC-AC converter selectively coupled to the electric motor via a seventh switch and an eighth switch and selectively coupled to the power outlet via a ninth switch, a tenth switch, and an eleventh switch; and a DC-DC converter coupled to the DC-AC converter and selectively coupled to the battery via a twelfth switch and a thirteenth switch. The charging port is selectively coupled to the battery via a thirteenth switch.

[0016] The on-board charging system may include one or more of the following optional features. For example, the positive terminal of the charging port is selectively coupled to the stator winding of the motor between the bidirectional inverter and the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to a half-bridge switch via a fourteenth switch.

[0017] According to at least one aspect, the positive terminal of the charging port is selectively coupled to the stator winding of the motor between the bidirectional inverter and the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to the capacitors of the bidirectional inverter via a fourteenth switch.

[0018] According to at least one example, the positive terminal of the charging port is selectively coupled to three sub-switches via a sixth switch, each of which is selectively coupled to a separate stator winding of the motor. The on-board charging system may also include a processor configured to monitor the temperature of the stator windings and selectively control the three sub-switches to prevent any stator winding from exceeding a threshold temperature.

[0019] According to another example, the positive terminal of the charging port is selectively coupled to the neutral point of the stator winding of the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to an insulated gate bipolar transistor connected in parallel with a bidirectional inverter, a DC-AC converter, and a DC-DC converter via a fourteenth switch.

[0020] According to at least one aspect, the positive terminal of the charging port is selectively coupled to the neutral point of the stator winding of the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled between the capacitors of the bidirectional inverter via a fourteenth switch.

[0021] Alternatively, one or more fuses may be positioned adjacent to the positive and negative terminals of the battery.

[0022] According to at least one example, one or more pre-charge resistors are positioned between the third switch and the bidirectional inverter.

[0023] According to another example, the on-board charging system may also include a battery disconnection unit configured to be controlled by a processor and including one or more switches, one or more resistors, and one or more fuses.

[0024] The following solutions are provided:

[0025] 1. An electric vehicle, comprising:

[0026] The charging port is configured to receive AC power;

[0027] A power outlet configured to provide AC power to one or more external devices;

[0028] A direct current (DC) battery, which is selectively coupled to a charging port via a first switch and a second switch;

[0029] A bidirectional inverter configured to convert AC power to DC power and DC power to AC power, the bidirectional inverter being selectively coupled to a battery via a third, fourth, and fifth switch;

[0030] An electric motor is coupled to a bidirectional inverter and selectively coupled to a charging port via a sixth switch;

[0031] A DC-AC converter that is selectively coupled to a motor via switches seven and eight and selectively coupled to a power socket via switches nine, ten and eleven.

[0032] A DC-DC converter, which is coupled to a DC-AC converter and selectively coupled to a battery via a twelfth and thirteenth switch;

[0033] The charging port is selectively coupled to a bidirectional inverter, a motor, or a DC-AC converter via a fourteenth switch; and

[0034] The processor is configured to control the operation of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth and fourteenth switches based on the operating mode of the electric vehicle.

[0035] 2. The electric vehicle according to Scheme 1, wherein one or more fuses are disposed adjacent to the positive and negative terminals of the battery.

[0036] 3. The electric vehicle according to Scheme 2, wherein during the vehicle-to-vehicle DC boost mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the seventh switch, the ninth switch, the tenth switch, the eleventh switch, the twelfth switch and the thirteenth switch in the open position, and puts the fourth switch, the fifth switch, the sixth switch and the fourteenth switch in the closed position.

[0037] 4. The electric vehicle according to Scheme 2, wherein during the vehicle-to-vehicle step-down mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the open position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

[0038] 5. The electric vehicle according to Scheme 2, wherein during the vehicle-to-load inverter module mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the sixth switch, the seventh switch, the eighth switch and the fourteenth switch in the open position, and puts the ninth switch, the tenth switch, the eleventh switch, the twelfth switch and the thirteenth switch in the closed position.

[0039] 6. The electric vehicle according to Scheme 2, wherein during the vehicle-to-grid mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the open position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

[0040] 7. The electric vehicle according to Scheme 2, wherein during the vehicle-to-home mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the off position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

[0041] 8. The electric vehicle according to Scheme 2, wherein during the AC charging mode of the electric vehicle, the processor puts the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch, the eleventh switch, the first switch and the second switch in the open position, and puts the twelfth switch, the thirteenth switch, the fourteenth switch, the sixth switch, the seventh switch and the eighth switch in the closed position.

[0042] 9. The electric vehicle according to Scheme 2, wherein during the propulsion mode of the electric vehicle, the processor puts the first switch, the second switch, the sixth switch, the seventh switch, the eighth switch, the ninth switch, the tenth switch, the eleventh switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the open position, and closes the third switch and the fifth switch to precharge the inverter capacitor, and then opens the third switch and closes the fourth switch.

[0043] 10. The electric vehicle according to Scheme 2, wherein during the DC fast charging mode of the electric vehicle, the processor puts the third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth and fourteenth switches in the open position, and puts the first and second switches in the closed position.

[0044] 11. An on-board charging system for an electric vehicle, the on-board charging system comprising:

[0045] The charging port is configured to receive AC power;

[0046] A power outlet configured to provide AC power to one or more external devices;

[0047] A direct current (DC) battery, which is selectively coupled to a charging port via a first switch and a second switch;

[0048] A bidirectional inverter configured to convert AC power to DC power and DC power to AC power, the bidirectional inverter being selectively coupled to a battery via a third, fourth, and fifth switch;

[0049] An electric motor is coupled to a bidirectional inverter and selectively coupled to a charging port via a sixth switch;

[0050] A DC-AC converter, selectively coupled to a motor via switches seven and eight and selectively coupled to a power outlet via switches nine, ten, and eleven; and

[0051] A DC-DC converter, coupled to a DC-AC converter and selectively coupled to a battery via twelfth and thirteenth switches; and

[0052] The charging port is selectively coupled to the battery via a thirteenth switch.

[0053] 12. The on-board charging system according to Scheme 11, wherein the positive terminal of the charging port is selectively coupled to the stator winding of the motor between the bidirectional inverter and the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to a half-bridge switch via a fourteenth switch.

[0054] 13. The on-board charging system according to Scheme 11, wherein the positive terminal of the charging port is selectively coupled to the stator winding of the motor between the bidirectional inverter and the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to the capacitors of the bidirectional inverter via a fourteenth switch.

[0055] 14. The on-board charging system according to Scheme 11, wherein the positive terminal of the charging port is selectively coupled to three sub-switches via a sixth switch, and each of the three sub-switches is selectively coupled to a separate stator winding of the motor.

[0056] 15. The on-board charging system according to claim 14 further includes a processor configured to monitor the temperature of the stator winding and selectively control three sub-switches to prevent any stator winding from exceeding a threshold temperature.

[0057] 16. The on-board charging system according to claim 11, wherein the positive terminal of the charging port is selectively coupled to the neutral point of the stator winding of the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled to an insulated gate bipolar transistor connected in parallel with a bidirectional inverter, a DC-AC converter and a DC-DC converter via a fourteenth switch.

[0058] 17. The on-board charging system according to Scheme 11, wherein the positive terminal of the charging port is selectively coupled to the neutral point of the stator winding of the motor via a sixth switch, and the negative terminal of the charging port is selectively coupled between the capacitors of the bidirectional inverter via a fourteenth switch.

[0059] 18. The on-board charging system according to claim 11, wherein one or more fuses are disposed adjacent to the positive and negative terminals of the battery.

[0060] 19. The on-board charging system according to Scheme 11, wherein one or more pre-charge resistors are disposed between the third switch and the bidirectional inverter.

[0061] 20. The on-board charging system according to claim 11 further includes a battery disconnection unit configured to be controlled by a processor and including one or more switches, one or more resistors and one or more fuses. Attached Figure Description

[0062] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0063] Figure 1 It is a perspective view of a vehicle including an on-board charging system according to the principles of this disclosure;

[0064] Figure 2 This is a schematic diagram of an on-board charging system based on the principles of this disclosure;

[0065] Figure 3A It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system;

[0066] Figure 3B It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system;

[0067] Figure 3C It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system;

[0068] Figure 3D It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system;

[0069] Figure 3E It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system; and

[0070] Figure 3F It is based on the principles of this disclosure. Figure 1 A schematic circuit diagram of the vehicle's on-board charging system.

[0071] In all the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0072] The example configuration will now be described more fully with reference to the accompanying drawings. The example configuration is provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configuration of this disclosure. It will be apparent to those skilled in the art that specific details are not required, the example configuration may be embodied in many different forms, and the specific details and example configuration should not be construed as limiting the scope of this disclosure.

[0073] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or illustrated, unless specifically identified as such. Additional or alternative steps may be employed.

[0074] When an element or layer is described as “located on another element or layer,” “joined to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly located on, joined to, connected to, attached to, or coupled to the other element or layer, or an intervening element or layer may be present. In contrast, when an element is described as “directly located on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, an intervening element or layer may not be present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0075] The terms “third,” “fourth,” “fifth,” etc., may be used herein to describe various elements, components, regions, layers, and / or segments. These elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Terms such as “third,” “fourth,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Therefore, without departing from the teachings of the example configuration, the third element, component, region, layer, or segment discussed below may be referred to as the fourth element, component, region, layer, or segment.

[0076] In this application (including the following definitions), the term "module" may be replaced by the term "circuit". The term "module" may refer to, be part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor (shared, dedicated, or group) for executing code; memory (shared, dedicated, or group) for storing code executed by the processor; other suitable hardware components that provide the described functionality; or some or all of the above, such as in a system-on-a-chip.

[0077] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" covers a single processor that executes some or all of the code from multiple modules. The term "group processor" covers a processor combined with an additional processor that executes some or all of the code from one or more modules. The term "shared memory" covers a single memory that stores some or all of the code from multiple modules. The term "group memory" covers memory combined with additional memory that stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium." The term "computer-readable medium" does not cover transient electrical and electromagnetic signals propagated through a medium, and therefore can be considered tangible and non-transitory memory. Non-limiting examples of non-transitory memory include tangible computer-readable media, including non-volatile memory, magnetic storage devices, and optical storage devices.

[0078] The apparatus and methods described in this application may be implemented, in part or in whole, by one or more computer programs executed by one or more processors. The computer program includes processor-executable instructions stored on at least one non-transitory, tangible computer-readable medium. The computer program may also include or depend on stored data.

[0079] A software application (i.e., a software resource) can refer to computer software that enables a computing device to perform tasks. In some examples, a software application may be referred to as an "application," "app," or "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0080] Non-transitory memory can be a physical device used for temporary or permanent storage of programs (e.g., sequences of instructions) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used in firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase-change memory (PCM), and magnetic disks or magnetic tapes.

[0081] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and may be implemented in high-level procedural and / or object-oriented programming languages ​​and / or in assembly / machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) used to provide machine instructions and / or data to a programmable processor, including machine-readable media that receive machine instructions as machine-readable signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0082] Various implementations of the systems and techniques described herein can be implemented as digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (Application-Specific Integrated Circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementations in one or more computer programs executable and / or interpretable on a programmable system comprising at least one programmable processor, which may be dedicated or general-purpose, coupled to receive data and instructions from a storage system, at least one input device, and at least one output device, and to transfer data and instructions to the storage system, at least one input device, and at least one output device.

[0083] The processes and logic described in this specification can be executed by one or more programmable processors (also known as data processing hardware) that execute one or more computer programs to perform functions by manipulating input data and generating output. Processing and logic can also be executed by special-purpose logic circuitry, such as FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits). As an example, processors suitable for executing computer programs include both general-purpose and special-purpose microprocessors, as well as any one or more processors in any kind of digital computer. Typically, the processor receives instructions and data from read-only memory or random access memory, or both. The basic elements of a computer are the processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include, or be operatively coupled to, receiving or transferring data to, or both to, one or more mass storage devices (such as magnetic disks, magneto-optical disks, or optical disks) for storing data. However, such devices are not essential for a computer. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, for example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks or removable disks; magneto-optical disks; and CD-ROMs and DVD-ROMs. Processors and memory may be supplemented by or incorporated into dedicated logic circuitry.

[0084] To provide interaction with a user, one or more aspects of this disclosure can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen) for displaying information to the user and optional keyboard and pointing devices (e.g., a mouse or trackball) through which the user can provide input to the computer. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback, such as visual, auditory, or tactile feedback; and input from the user can be received in any form, including sound, speech, or tactile input. Furthermore, the computer can interact with the user by sending documents to and receiving documents from devices used by the user; for example, by sending web pages to a web browser on the user's client device in response to a request received from a web browser.

[0085] refer to Figure 1A schematic diagram of a vehicle 10 used in conjunction with one or more principles of this disclosure is provided. The vehicle 10 includes an on-board charging system 100, which includes a processor 102, a charging port 104, a power socket 106, a battery 108, and an electric motor 110. In at least one configuration, the vehicle 10 is a hybrid vehicle utilizing an internal combustion engine and an electric motor. In another configuration, the vehicle 10 is an electric vehicle utilizing only the electric motor. The vehicle 10 can be configured to connect via the charging port 104 to a single-phase or three-phase alternating current (AC) power source for charging the battery 108. The electric motor 110 can be configured to receive power from the battery 108 to provide propulsion for the vehicle 10. In at least one configuration, the battery 108 can be configured to supply direct current (DC) power to an inverter that converts the DC power into three-phase AC power. The three-phase AC power is supplied to the electric motor 110 for propulsion of the vehicle 10.

[0086] refer to Figure 2 An example of an on-board charger system 200 is shown according to aspects of this disclosure. As shown, the on-board charger system 200 includes a processor 202, a charging port 204, a power socket 206, a battery 208, a motor 210, a DC-AC converter 212, a DC-DC converter 214, a bidirectional inverter 216, and one or more switches S1-S2. n .

[0087] Charging port 204 can be configured to receive single-phase AC power, three-phase AC power, or DC power (e.g., DC fast charging) from a charging source. In one configuration, the single-phase AC power has a voltage between 85 volts and 270 volts. In another configuration, the three-phase AC power and / or DC power for fast charging has a voltage between 300 volts and 900 volts. In one configuration, charging port 204 includes one or more sensors (not shown) configured to detect that a charging source has been connected to charging port 204. In one configuration, the sensors communicate with processor 202. As will be discussed in one or more of the following configurations, the positive terminal of charging port 204 can be connected via a fourteenth switch S. 14 It is selectively coupled to the bidirectional inverter 216, the motor 210, and / or the DC-AC converter 212. Furthermore, the charging port 204 can be selectively coupled to the battery 208 via a first switch S1 and a second switch S2.

[0088] Power socket 206 is connected to the ninth switch S9 and the tenth switch S 10 and the eleventh switch S 11Selectively coupled to DC-AC converter 212. For example, power outlet 206 can be configured to provide split-phase AC power to one or more mobile devices when the vehicle is in motion and stationary. In one configuration, the split-phase AC power has a voltage between 120 volts and 270 volts. DC-AC converter 212 can also be selectively coupled to motor 210 via seventh switch S7 and eighth switch S8.

[0089] Battery 208 can be a direct current (DC) battery, which is a high-voltage battery and has a capacity greater than approximately 300 volts. In one configuration, the battery is a lithium-ion battery. Battery 208 may include one or more NCM (lithium nickel manganese cobalt oxide) battery cells, one or more LFP (lithium iron phosphate) battery cells, and other types of battery cells.

[0090] The bidirectional inverter 216 is configured to convert AC power to DC power and vice versa. The bidirectional inverter 216 is selectively coupled to the DC battery 208 via a third switch S3, a fourth switch S4, and a fifth switch S5. The term "bidirectional" indicates that the bidirectional inverter 216 can operate in both directions, allowing power to flow into and out of the battery 208.

[0091] In AC-to-DC or rectification mode, the bidirectional inverter 216 converts AC power from the motor 210 into DC power. The AC input from the motor 210 is connected to the bidirectional inverter 216, which in turn connects to the DC-AC converter 212 and the DC-DC converter 214. The isolated DC-DC converter 214 is connected via a twelfth switch S. 12 and the thirteenth switch S 13 Connected to battery 208. The rectifier of bidirectional inverter 216 uses power electronic switches (e.g., insulated-gate bipolar transistors or IGBTs) to convert AC input to DC.

[0092] In DC-to-AC mode or inverter mode, the bidirectional inverter 216 converts DC power from battery 208 into AC power. The DC output from battery 208 is connected to the bidirectional inverter 216 via a fifth switch S5. The inverter of the bidirectional inverter 216 uses power electronic switches (e.g., insulated-gate bipolar transistors (IGBTs), wideband gap switches, etc.) to convert the DC input to AC. For example, the bidirectional inverter 216 can use pulse width modulation (PWM) technology to convert DC power into a high-frequency AC waveform. In some configurations, the bidirectional inverter 216 includes control circuitry that regulates the AC output voltage and frequency to match the requirements of motor 210.

[0093] For example, the on-board charging system 200 can utilize one or more electric motors 210 to provide propulsion for the electric vehicle 10 and charge the battery 208. In one configuration, the electric motor 210 is selectively coupled to the charging port 204 via a sixth switch S6. In some configurations, AC power can be provided to the stator windings of the electric motor 210 or to the neutral point of the stator windings of the electric motor 210. The stator windings can act as an inductor for the provided AC power.

[0094] The processor 202 controls the operation of the on-board charging system 200's switch (i.e., opening and / or closing) (i.e., opening and closing the switch according to the vehicle 10's operating mode). Several operating modes of the on-board charging system 200 are provided below.

[0095] In the vehicle-to-vehicle (V2V) DC boost mode of electric vehicle 10, processor 202 first closes the third switch S3 and the fifth switch S5 to precharge the capacitor of inverter 216, then opens the third switch S3 and closes the fourth switch S4 and the fourteenth switch S5. 14 And the sixth switch S6 allows DC power to flow from the charging port 204 through the motor 210 and the bidirectional inverter 216, which provides DC power to the battery 208.

[0096] In the vehicle-to-vehicle (V2V) step-down mode of electric vehicle 10, processor 202 closes the twelfth switch S. 12 13th switch S 13 Fourteenth switch S 14 The sixth switch S6, the seventh switch S7, and the eighth switch S8 allow DC power to flow from the charging port 204 through the motor 210 and the bidirectional inverter 216. At this point, the DC-DC converter 214 can convert the DC power to a voltage level compatible with the battery 208 and then charge the battery 208.

[0097] According to one aspect, in the vehicle-to-load inverter module (V2Lim) mode of electric vehicle 10, processor 202 closes the twelfth switch S. 12 13th switch S 13 Ninth switch S9, tenth switch S 10 and the eleventh switch S 11 This allows DC power to flow from DC-DC converter 214 to DC-AC converter 212, so that AC power is supplied to power outlet 206.

[0098] According to another aspect, in the vehicle-to-load inverter module (V2Lim) mode during the propulsion of the electric vehicle 10, the processor 202 closes the fourth switch S4, the fifth switch S5, and the twelfth switch S6. 12 13th switch S 13Ninth switch S9, tenth switch S 10 and the eleventh switch S 11 This allows DC power to flow from battery 208 to inverter 216 and motor 210 to provide propulsion. Additionally, DC power flows from DC-DC converter 214 to DC-AC converter 212, so that AC power is supplied to power outlet 206.

[0099] According to another aspect, in the vehicle-to-load inverter module (V2Lim) mode, when charging the electric vehicle 10, the processor 202 closes the sixth switch S6, the seventh switch S7, the eighth switch S8, the ninth switch S9, and the tenth switch S10. 10 Eleventh switch S 11 12th switch S 12 13th switch S 13 and the fourteenth switch S 14 This allows AC power to flow from the charging port to the inverter 216 and the motor 210. The inverter 216 can operate in rectifier mode, while the stator windings of the motor 210 act as inductors to convert the AC power to DC power. The DC-DC converter 214 can then convert the DC power to a voltage level compatible with the battery 208 to charge the battery 208. Furthermore, DC power can flow from the motor 208 and the inverter 216, and from the DC-AC converter 212 to the power socket 206, allowing AC power to be supplied to the power socket 206.

[0100] In the vehicle-to-grid (V2G) mode or vehicle-to-home (V2H) mode of electric vehicle 10, processor 202 switches the twelfth switch S. 12 13th switch S 13 Fourteenth switch S 14 The sixth switch S6, the seventh switch S7, and the eighth switch S8 allow DC power to flow from the battery 208 to the DC-DC converter 214, through the DC-AC converter 212 to the motor 210 and the inverter 216, where the DC power is converted into AC power and output to the grid or home through the charging port.

[0101] In the AC charging mode of electric vehicle 10, processor 202 closes the twelfth switch S. 12 13th switch S 13 Fourteenth switch S 14Switches S6, S7, and S8 allow AC power to flow from charging port 204 to motor 210 and inverter 216. Inverter 216 can operate in rectifier mode, while the stator windings of motor 210 can be used as inductors to convert AC power to DC power. At this point, DC-DC converter 214 can convert the DC power to a voltage level compatible with battery 208 to charge battery 208.

[0102] In the propulsion mode of the electric vehicle 10, the processor 202 first closes the third switch S3 and the fifth switch S5 to precharge the capacitor of the inverter 216. Then, the processor 202 can open the third switch S3 and close the fourth switch S4 to allow DC power to flow from the battery 208 through the bidirectional inverter 216, which provides AC power to the motor 210.

[0103] In the normal DC fast charging (DCFC) mode of vehicle 10, processor 202 closes the first switch S1 and the second switch S2, allowing DC power to flow from charging port 204 to battery 208.

[0104] In some configurations, more than one mode can be used simultaneously. For example, processor 202 can close the twelfth switch S. 12 13th switch S 13 Ninth switch S9, tenth switch S 10 Eleventh switch S 11 The first switch S1 and the second switch S2 allow simultaneous use of normal DCFC and vehicle-to-load inverter module mode. In other words, passengers can use the power outlet 206 to charge personal devices (e.g., cellular phones or computers) while simultaneously charging the vehicle 10's battery 208.

[0105] Figure 3A , 3B 3C, 3D, 3E, and 3F each show circuit diagrams of example configurations of on-board charging systems 300, 300A-300F according to the principles of this disclosure. On-board charging system 300 includes a charging port 304, a power socket 306, a battery 308, a motor 310, a DC-DC converter 312, a DC-AC converter 314, a bidirectional inverter 316, one or more pre-charge resistors 318, one or more fuses 320, and switches S1-S2. n and capacitor C1-C n The on-board charging system 300 may also include a battery disconnection unit 322, which includes switches S1-S5, S... 12 and S 13 One or more 318 resistors and one or more fuses.

[0106] In one configuration, such as Figure 3A As shown, the positive terminal of the charging port 304 of the on-board charging system 300A is selectively coupled to the stator winding 311 of the motor 310 between the bidirectional inverter 316 and the motor 310 via the sixth switch S6. The negative terminal of the charging port 304 of the on-board charging system 100 is connected to the stator winding 311 of the motor 310 via the fourteenth switch S6. 14 Selectively coupled to half-bridge switch 324 (i.e., IGBT), half-bridge switch 324 is connected in parallel to bidirectional inverter 316, DC-AC converter 314 and DC-DC converter 312. In addition, the positive terminal of charging port 304 is selectively coupled to the battery via first switch S1, and the negative terminal is selectively coupled to the battery via second switch S2.

[0107] In one configuration, such as Figure 3B As shown, the positive terminal of the charging port 304 of the on-board charging system 300B is selectively coupled between a stator winding 311 of the motor 310 and the bidirectional inverter 316 via a sixth switch S6. In this configuration, the capacitor of the bidirectional inverter 316 is divided into two capacitors C1 and C5, and the negative terminal of the charging port 304 of the on-board charging system 300B is connected via a fourteenth switch S5. 14 The capacitors C1 and C5 of the bidirectional inverter 316 are selectively coupled. In addition, the positive terminal of the charging port 304 is selectively coupled to the battery 308 via the first switch S1, and the negative terminal is selectively coupled to the battery 308 via the second switch S2.

[0108] In some cases, Figure 3B The configuration shown may cause one stator winding 311 of the motor 310 connected to the positive terminal of the charging port 304 to overheat, which could negatively impact charging performance and / or the performance of the motor 310. Therefore, in another configuration, such as Figure 3C As shown, the positive terminal of the charging port 304 of the on-board charging system 300C is selectively coupled to three separate sub-switches S via a sixth switch S6. 6a S 6b S 6c These three sub-switches S 6a S 6b S 6c Selectively coupled between the stator winding 311 of the motor 310 and the bidirectional inverter 316. In this configuration, three sub-switches S 6a S 6b S 6c Actively controlled by a processor (not shown), so that at any time the three sub-switches S 6a S 6b S 6cOnly one of the three sub-switches is closed. A processor (not shown) is configured to monitor the temperature of the stator winding 311 of the motor 310 and selectively control the three sub-switches S. 6a S 6b S 6c This is to prevent any stator winding 311 of the motor 310 from exceeding a threshold temperature. In this configuration, the capacitors of the bidirectional inverter 316 are divided into two capacitors C1 and C5, and the negative terminal of the charging port 304 of the on-board charging system 300C is selectively coupled between the two capacitors C1 and C5 of the bidirectional inverter 316. Furthermore, the positive terminal of the charging port 304 is selectively coupled to the battery 308 via a first switch S1, and the negative terminal is selectively coupled to the battery 308 via a second switch S2.

[0109] In one configuration, such as Figure 3D As shown, the positive terminal of the charging port 304 of the on-board charging system 300D is selectively coupled to the neutral point of the stator winding 311 of the motor 310 via the sixth switch S6. The negative terminal of the charging port 304 of the on-board charging system 300D is selectively coupled to the neutral point of the stator winding 311 of the motor 310 via the fourteenth switch S6. 14 The IGBTs are selectively coupled to the bidirectional inverter 316, the DC-AC converter 314, and the DC-DC converter 312. Furthermore, the positive terminal of the charging port 304 is selectively coupled to the battery 308 via a first switch S1, and the negative terminal is selectively coupled to the battery 308 via a second switch S2.

[0110] In one configuration, such as Figure 3E As shown, the positive terminal of the charging port 304 of the on-board charging system 300E is selectively coupled to the neutral point of the stator winding 311 of the motor 310 via the sixth switch S6. In this configuration, the capacitor of the bidirectional inverter 316 is divided into two capacitors C1 and C5, and the negative terminal of the charging port 304 is connected via the fourteenth switch S1. 14 The capacitors C1 and C5 of the bidirectional inverter 316 are selectively coupled. In addition, the positive terminal of the charging port 304 is selectively coupled to the battery 308 via the first switch S1, and the negative terminal is selectively coupled to the battery 308 via the second switch S2.

[0111] In one configuration, such as Figure 3F As shown, the charging port 304 of the on-board charging system 300F can be configured for three-phase AC power, and is connected via the motor 310 and a relay switch (i.e., the fifteenth switch S). 15 and the sixteenth switch S 16 The three switches S between) 6e S 6d S 6fThe stator winding 311 of the motor 310 is selectively coupled. In addition, the positive terminal of the charging port 304 is selectively coupled to the battery 308 via a first switch S1, and the negative terminal is selectively coupled to the battery 308 via a second switch S2.

[0112] In some configurations, one or more fuses 320 are disposed adjacent to the terminals of battery 308 and configured to prevent damage to battery 308 by preventing current exceeding a threshold level from flowing into or out of battery 308. In one configuration, one or more pre-charge resistors 318 are disposed between one of the switches (e.g., the third switch S3) and bidirectional inverter 316. The pre-charge resistors 318 may be configured to slowly charge capacitors C1 and / or C5 of bidirectional inverter 316 before bidirectional inverter 316 is powered on, and to prevent large current from flowing into bidirectional inverter 316.

[0113] Figure 3A , 3B The various configurations of the on-board charging systems 300, 300A-300F shown in 3C, 3D, 3E and 3F are provided as examples of on-board charging systems and are not intended to be limiting. Those skilled in the art will understand that other configurations of the on-board charging system 300 according to the principles of this disclosure are possible.

[0114] Many embodiments have been described. However, it will be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are also within the scope of the appended claims.

[0115] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, they are interchangeable and can be used in selected configurations, even if not specifically shown or described. This can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. An electric vehicle, comprising: The charging port is configured to receive AC power; A power outlet configured to provide AC power to one or more external devices; A direct current (DC) battery, which is selectively coupled to a charging port via a first switch and a second switch; A bidirectional inverter configured to convert AC power to DC power and DC power to AC power, the bidirectional inverter being selectively coupled to a battery via a third, fourth, and fifth switch; An electric motor is coupled to a bidirectional inverter and selectively coupled to a charging port via a sixth switch; A DC-AC converter that is selectively coupled to a motor via switches seven and eight and selectively coupled to a power socket via switches nine, ten and eleven. A DC-DC converter, which is coupled to a DC-AC converter and selectively coupled to a battery via a twelfth and thirteenth switch; The charging port is selectively coupled to a bidirectional inverter, a motor, or a DC-AC converter via a fourteenth switch. as well as The processor is configured to control the operation of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth and fourteenth switches based on the operating mode of the electric vehicle.

2. The electric vehicle according to claim 1, wherein one or more fuses are disposed adjacent to the positive and negative terminals of the battery.

3. The electric vehicle according to claim 2, wherein during the vehicle-to-vehicle DC boost mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the seventh switch, the ninth switch, the tenth switch, the eleventh switch, the twelfth switch, and the thirteenth switch in the open position, and puts the fourth switch, the fifth switch, the sixth switch, and the fourteenth switch in the closed position.

4. The electric vehicle according to claim 2, wherein during the vehicle-to-vehicle buck mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the open position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

5. The electric vehicle according to claim 2, wherein during the vehicle-to-load inverter module mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the sixth switch, the seventh switch, the eighth switch, and the fourteenth switch in the open position, and puts the ninth switch, the tenth switch, the eleventh switch, the twelfth switch, and the thirteenth switch in the closed position.

6. The electric vehicle according to claim 2, wherein during the vehicle-to-grid mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the open position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

7. The electric vehicle according to claim 2, wherein during the vehicle-to-home mode of the electric vehicle, the processor puts the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch and the eleventh switch in the off position, and puts the sixth switch, the seventh switch, the eighth switch, the twelfth switch, the thirteenth switch and the fourteenth switch in the closed position.

8. The electric vehicle according to claim 2, wherein during the AC charging mode of the electric vehicle, the processor puts the third switch, the fourth switch, the fifth switch, the ninth switch, the tenth switch, the eleventh switch, the first switch and the second switch in the off position, and puts the twelfth switch, the thirteenth switch, the fourteenth switch, the sixth switch, the seventh switch and the eighth switch in the closed position.

9. The electric vehicle according to claim 2, wherein during the propulsion mode of the electric vehicle, the processor puts the first switch, second switch, sixth switch, seventh switch, eighth switch, ninth switch, tenth switch, eleventh switch, twelfth switch, thirteenth switch and fourteenth switch in the open position, and closes the third switch and fifth switch to precharge the inverter capacitor, and then opens the third switch and closes the fourth switch.

10. The electric vehicle according to claim 2, wherein during the DC fast charging mode of the electric vehicle, the processor puts the third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth and fourteenth switches in the off position and puts the first and second switches in the closed position.

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