Control of starting operation in electric vehicle

Abstract

The invention relates to control of start operation in an electric vehicle. A system for controlling a start operation of an electric vehicle includes a high voltage electric propulsion unit and a controller. A high voltage electrical propulsion unit includes at least one battery pack, a high voltage bus, one or more power components, a first set of switches, and a second set of switches. The on-board charger is adapted to deliver an adjustable current to pre-charge the high voltage bus during a start-up operation. A first set of switches selectively connects the at least one battery pack to a boost high voltage (HV) bus, and a second set of switches selectively connects the at least one battery pack to a charge port high voltage (HV) bus. The controller is adapted to control operation of the first set of switches and the second set of switches so as to enable pre-charging of the high voltage bus during a start-up operation.

Description

Background Technology

[0001] This disclosure relates to a system and method for controlling the start-up operation of an electric vehicle. The use of mobile platforms employing rechargeable energy sources as both dedicated and non-dedicated energy sources has increased significantly in recent years. Rechargeable energy storage devices in electric vehicles can store and release electrochemical energy as needed during a given operating mode. This electrochemical energy can be used for propulsion, heating or cooling compartments, powering vehicle accessories, and other purposes. Electric vehicles typically include dedicated pre-charging circuits used in the start-up of high-voltage propulsion systems. Summary of the Invention

[0002] This document discloses a system for controlling the start-up operation of an electric vehicle having a high-voltage electric propulsion unit. The high-voltage electric propulsion unit includes at least one battery pack (hereinafter referred to as "at least one"), a high-voltage bus, one or more power components, a first set of switches, and a second set of switches. An on-board charger is adapted to deliver an adjustable current during start-up operation to pre-charge the high-voltage bus. A charging port is directly coupled to the input of the on-board charger. A controller communicates with the on-board charger and has a processor and a tangible non-transitory memory thereon recording instructions for selectively executing one or more modes. The first set of switches selectively connects the at least one battery pack to the propulsion high-voltage (HV) bus, and the second set of switches selectively connects the at least one battery pack to the charging port high-voltage (HV) bus. The controller is adapted to control the operation of the first and second sets of switches to enable pre-charging of the high-voltage bus during start-up operation.

[0003] An electric vehicle can be defined without a dedicated pre-charge circuit for startup operations on a high-voltage drive bus. Power components may include an accessory power module and at least one power inverter module. The on-board charger is adapted to operate based on both DC and AC input voltages from the charging port. The on-board charger can be configured to allow bidirectional current flow.

[0004] In some embodiments, a first set of switches selectively connects the DC output of the on-board charger to the battery pack. The first set of switches can also selectively disconnect the at least one battery pack from the propulsion HV bus. A second set of switches is adapted to isolate the charging port and the charging port HV bus from the at least one battery pack when the electric vehicle is off or in driving mode. The controller is adapted to enable the on-board charger by setting the output current of the on-board charger to a predefined permissible precharge current and setting the output voltage limit of the on-board charger to the battery voltage of the at least one battery pack.

[0005] The mode may include a propulsion mode. Execution of the propulsion mode includes: verifying that the first and second sets of switches are off and the charging port is unplugged; closing the second set of switches and enabling the on-board charger. Execution of the propulsion mode includes: closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment of the battery voltage; disabling the on-board charger, turning off the second set of switches, and setting the propulsion command.

[0006] The mode may include a direct current (DC) charging mode. Execution of the DC charging mode includes: verifying that the first and second sets of switches are off and that the on-board charger is connected to the charging port. Execution of the DC charging mode includes: commanding the charger to apply a voltage equal to the battery voltage and enabling the on-board charger; closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment of the battery voltage. Execution of the DC charging mode includes: disabling the on-board charger, closing the second set of switches, and requesting DC charging current from an external charger.

[0007] The mode may include an AC charging mode. Execution of the AC charging mode includes: verifying that the first set of switches and the second set of switches are off and that the on-board charger is connected to the charging port. Execution of the AC charging mode includes: commanding the charger to apply a voltage equal to the battery voltage and activating the on-board charger. Execution of the AC charging mode includes: closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment of the battery voltage; returning the on-board charger to standby mode; and requesting AC charging current.

[0008] This document discloses a method for controlling the start-up operation of an electric vehicle having a high-voltage electric propulsion unit, an on-board charger, and a controller having a processor and tangible non-transitory memory. The method includes connecting at least one battery pack, a high-voltage bus, one or more power components, a first set of switches, and a second set of switches within the high-voltage electric propulsion unit. The method includes directly coupling a charging port to a charger input of the on-board charger; and delivering an adjustable current via the on-board charger to pre-charge the high-voltage bus during the start-up operation. The method includes selectively connecting the at least one battery pack to the propulsion high-voltage (HV) bus via the first set of switches; and selectively connecting the at least one battery pack to the charging port high-voltage (HV) bus via the second set of switches. The method includes controlling the operation of the first set of switches and the second set of switches via the controller to enable pre-charging of the high-voltage bus during the start-up operation.

[0009] According to embodiments of this disclosure, a system for controlling the start-up operation of an electric vehicle is provided, the system comprising: a high-voltage electric propulsion unit including at least one battery pack, a high-voltage bus, one or more power components, a first set of switches, and a second set of switches; an on-board charger adapted to deliver an adjustable current to precharge the high-voltage bus during the start-up operation; a charging port directly coupled to an input of the on-board charger; and a controller communicating with the on-board charger, the controller having a processor and a tangible non-transitory memory thereon recording instructions for selectively executing one or more modes; wherein the first set of switches selectively connects the at least one battery pack to the propulsion high-voltage (HV) bus, and the second set of switches selectively connects the at least one battery pack to the charging port high-voltage (HV) bus; and wherein the controller is adapted to control the operation of the first set of switches and the second set of switches to enable precharging of the high-voltage bus during the start-up operation.

[0010] According to embodiments of this disclosure, the electric vehicle is defined by the absence of a dedicated pre-charging circuit for the startup operation on the high-voltage bus.

[0011] According to embodiments of this disclosure, the one or more power components include an accessory power module and at least one power inverter module.

[0012] According to embodiments of this disclosure, the vehicle charger is adapted to operate according to both a DC input voltage and an AC input voltage from the charging port.

[0013] According to embodiments of this disclosure, the on-board charger is configured to allow bidirectional current flow.

[0014] According to embodiments of this disclosure, the first set of switches selectively connects the DC output of the on-board charger to the at least one battery pack; the first set of switches selectively disconnects the at least one battery pack from the propulsion HV bus; and the second set of switches is adapted to isolate the charging port and the charging port HV bus from the at least one battery pack when the electric vehicle is turned off or in driving mode.

[0015] According to embodiments of this disclosure, the controller is adapted to enable the on-board charger by setting the output current of the on-board charger to a predefined permissible precharge current and setting the output voltage limit of the on-board charger to the battery voltage of the at least one battery pack.

[0016] According to embodiments of this disclosure, the one or more modes include a propulsion mode, the execution of which includes: verifying that the first set of switches and the second set of switches are off and the charging port is unplugged; closing the second set of switches and enabling the on-board charger; closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage; and disabling the on-board charger, turning off the second set of switches, and setting a propulsion command.

[0017] According to embodiments of this disclosure, the one or more modes include a direct current (DC) charging mode, the execution of which includes: verifying that the first set of switches and the second set of switches are off and that the on-board charger is connected to the charging port; commanding the charger to apply a voltage equal to the battery voltage and enabling the on-board charger; closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage; and disabling the on-board charger, closing the second set of switches, and requesting DC charging current from an external charger.

[0018] According to embodiments of this disclosure, the one or more modes include an AC charging mode, the execution of which includes: verifying that the first set of switches and the second set of switches are off and that the on-board charger is connected to the charging port; commanding the charger to apply a voltage equal to the battery voltage and enabling the on-board charger; closing the first set of switches when the bus voltage across the push HV bus is within a predefined increment of the battery voltage; and returning the on-board charger to a standby mode and requesting AC charging current.

[0019] According to embodiments of this disclosure, a method for controlling the start-up operation of an electric vehicle is provided, the electric vehicle having a high-voltage electric propulsion unit, an on-board charger, and a controller, the controller having a processor and a tangible non-transitory memory, the method comprising: connecting at least one battery pack, a high-voltage bus, one or more power components, a first set of switches, and a second set of switches in the high-voltage electric propulsion unit; directly coupling a charging port to a charger input of the on-board charger; delivering an adjustable current via the on-board charger to pre-charge the high-voltage bus during the start-up operation; selectively connecting the at least one battery pack to the propulsion high-voltage (HV) bus via the first set of switches; selectively connecting the at least one battery pack to the charging port high-voltage (HV) bus via the second set of switches; and controlling the operation of the first set of switches and the second set of switches via the controller to enable pre-charging of the high-voltage bus during the start-up operation.

[0020] According to embodiments of this disclosure, the method further includes: incorporating an accessory power module and at least one power inverter module into the one or more power components, defining the electric vehicle via a dedicated pre-charge circuit for the start-up operation that does not exist for the high-voltage bus.

[0021] According to embodiments of this disclosure, the method further includes: isolating the charging port from the at least one battery pack via the second set of switches during driving and off modes of the electric vehicle; adapting the on-board charger to operate according to a DC input voltage and an AC input voltage from the charging port; and configuring the on-board charger to allow bidirectional current flow.

[0022] According to embodiments of this disclosure, the method further includes: enabling the on-board charger via the controller by setting the output current of the on-board charger to a predefined allowable pre-charge current and setting the output voltage limit of the on-board charger to the battery voltage of the at least one battery pack, wherein the first set of switches defines the push HV bus when the first set of switches is closed.

[0023] According to embodiments of this disclosure, the method further includes: executing a propulsion mode via the controller, including: verifying that the first set of switches and the second set of switches are off and the charging port is unplugged; closing the second set of switches and enabling the on-board charger; closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage; and disabling the on-board charger, turning off the second set of switches, and setting a propulsion command.

[0024] According to embodiments of this disclosure, the method further includes: executing a DC charging mode via the controller, comprising: verifying that the first set of switches and the second set of switches are off and that the on-board charger is connected to the charging port; commanding the charger to apply a voltage equal to the battery voltage and enabling the on-board charger; closing the first set of switches when the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage; and disabling the on-board charger, closing the second set of switches, and requesting DC charging current.

[0025] According to embodiments of this disclosure, the method further includes: executing an AC charging mode via the controller, including: verifying that the first set of switches and the second set of switches are off and that the on-board charger is connected to the charging port; enabling the on-board charger; closing the first set of switches when the bus voltage across the push HV bus is within a predefined increment value of the battery voltage; and returning the on-board charger to standby mode and requesting AC charging current.

[0026] According to embodiments of this disclosure, an electric vehicle is provided, comprising: a high-voltage electric propulsion unit including at least one battery pack, a high-voltage bus, one or more power components, a first set of switches, and a second set of switches; an on-board charger adapted to deliver an adjustable current to precharge the high-voltage bus during startup operation; a charging port directly coupled to an input of the on-board charger; and a controller communicating with the on-board charger, the controller having a processor and a tangible non-transitory memory thereon recording instructions for selectively executing one or more modes; wherein the first set of switches selectively connects the at least one battery pack to the propulsion high-voltage (HV) bus; wherein the second set of switches selectively connects the at least one battery pack to the charging port high-voltage (HV) bus; and wherein the controller is adapted to control the operation of the first set of switches and the second set of switches to enable precharging of the high-voltage bus during startup operation.

[0027] According to embodiments of this disclosure, the second set of switches is adapted to isolate the charging port from the at least one battery pack during driving and off modes of the electric vehicle; and wherein the electric vehicle is defined by the absence of a dedicated pre-charging circuit for the start-up operation of the high-voltage bus.

[0028] According to embodiments of this disclosure, the vehicle charger is adapted to operate according to both a DC input voltage and an AC input voltage from the charging port, and the vehicle charger is configured to allow bidirectional current flow.

[0029] The above features and advantages, as well as other features and advantages, of this disclosure will readily become apparent from the following detailed description of the best mode for carrying out this disclosure when taken in conjunction with the accompanying drawings. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of a system for controlling the operation of a high-voltage electric propulsion unit in an electric vehicle, the system having a controller;

[0031] Figure 2 It is possible to be Figure 1 A schematic flowchart of the first and second modes executed by the controller;

[0032] Figure 3 It is possible to be Figure 1 A schematic flowchart of the third mode executed by the controller;

[0033] Figure 4 It is possible to be Figure 1 A schematic flowchart of the fourth mode executed by the controller; and

[0034] Figure 5 It is possible to be Figure 1 A schematic flowchart of the fifth mode executed by the controller.

[0035] Representative embodiments of this disclosure are shown in the accompanying drawings as non-limiting examples and are described in further detail below. However, it should be understood that the novel aspects of this disclosure are not limited to the specific forms illustrated in the drawings listed above. Rather, this disclosure is intended to cover modifications, equivalents, combinations, sub-combinations, arrangements, groupings, and substitutions that fall within the scope of this disclosure as covered, for example, by the appended claims. Detailed Implementation

[0036] Referring to the accompanying drawings, similar reference numerals indicate similar parts. Figure 1 The diagram schematically illustrates a system 10 for controlling the start-up operation of an electric vehicle 12 having a high-voltage electric propulsion unit 14. It is understood that the electric vehicle 12 may be partially or fully electric and may include a variety of energy sources. The electric vehicle 12 may be a mobile platform, such as, but not limited to, passenger vehicles, sport utility vehicles, light trucks, heavy vehicles, ATVs, minivans, buses, transit vehicles, bicycles, mobile robots, agricultural implements (e.g., tractors), sports-related equipment (e.g., golf carts), boats, aircraft, and trains. The electric vehicle 12 may take many different forms and has additional components.

[0037] Reference Figure 1 The high-voltage electric propulsion unit 14 includes a high-voltage bus 16, multiple power components 18, and at least one battery pack 20 (e.g., a high-voltage battery cell). The power components 18 may include, but are not limited to, an accessory power module (APM) 22, a heating module (HE) 24, an air conditioning electronic compressor (ACEC) module 26, and a power inverter module (e.g., a rear power inverter module 28 and a front power inverter module 30).

[0038] Electric vehicles typically include dedicated pre-charge circuitry, such as a pre-charge relay and a series resistor across the main high-voltage relay, which is used to minimize inrush current drawn by capacitive elements within the multiple power components 18 operating off based on the high-voltage bus 16 during startup. System 10 is able to pre-charge the high-voltage bus 16 in the electric vehicle 12 during startup operation without using the dedicated pre-charge circuitry. In other words, system 10 eliminates the physical structure (pre-charge circuitry) while retaining its functionality.

[0039] Reference Figure 1 The on-board charger 32 (sometimes referred to as an on-board charging module or "OBCM") is adapted to deliver an adjustable current during startup operation to precharge the high-voltage bus 16. See reference... Figure 1Vehicle 12 is capable of DC fast charging, in which the battery pack 20 is electrically connected to an external charger or off-board DC fast charging station (not shown) via charging port 34. On-board charger 32 is adapted to receive, or can operate based on, a DC input voltage and an AC input voltage from charging port 34. (See reference...) Figure 1 The high-voltage electric propulsion unit 14 includes one or more switches S to selectively connect the battery pack 20 to the charging port 34 (e.g., a combined DC / AC charging port, such as a North American Charging System-NACS standard socket).

[0040] In the illustrated embodiment, switch S includes a first set of switches (SA1, SA2) and a second set of switches (SB1, SB2). See also... Figure 1 The first set of switches (SA1, SA2) selectively connects battery pack 20 to the drive high-voltage (HV) buses 42A, 42B. The second set of switches (SB1, SB2) selectively connects battery pack 20 to the charging port high-voltage buses 40A, 40B (or charger input lines L1, L2) (also referred to herein as DC fast charging high-voltage (HV) buses 40A, 40B). The second set of switches (SB1, SB2) is adapted to isolate the charging port and charging port HV buses from battery pack 20 when the electric vehicle 12 is off or in driving mode.

[0041] Reference Figure 1 System 10 includes a controller C having at least one processor P and at least one memory M (or a non-transitory tangible computer-readable storage medium) on which instructions are recorded. The memory M stores a set of controller-executable instructions, and the processor P can execute the set of controller-executable instructions stored in the memory M. The controller C is adapted to control the operation of a first set of switches (SA1, SA2) and a second set of switches (SB1, SB2) to enable pre-charging of the high-voltage bus 16 during startup operation.

[0042] As described below, when pre-charging is enabled, the second set of switches (SB1, SB2) is closed to connect the charger input of the on-board charger 32 to the battery pack 20. The charger output can be commanded to ramp up using a constant current charge from the capacitors on the high-voltage bus. Alternatively, a ramp output voltage command can be used on the on-board charger 32 to gradually increase the bus voltage until it matches the battery voltage.

[0043] Once pre-charging is complete, the on-board charger 32 and the first set of switches (SA1, SA2) are disconnected, and the power components 18 on the high-voltage bus 16 can be operated according to commands from the vehicle propulsion controller. During vehicle charging, the high-voltage bus 16 can be pre-charged directly from the (AC / DC) charging port 34 via the on-board charger 32. The on-board charger 32 can be configured to allow bidirectional current flow (e.g., AC / DC input on the first port to DC output on the second port, or DC input on the second port to AC / DC output on the first port).

[0044] It is understood that the number of switches(one or more) in a group may vary depending on the application. In some embodiments, a “group” may include a single switch. Switch S may take different forms. In some embodiments, switch S includes at least one electromechanical contactor. Switch S may include at least one solid-state switch and / or diode. Switch S may include a contactor as an electrically operated switch or a relay as an electromagnetic switch.

[0045] System 10 may include an energy source 44 (e.g., a 12-volt battery) to precharge battery pack 20. See reference. Figure 1 The high-voltage electric propulsion unit 14 is coupled to the electric motor 46, which generates torque. The system 10 may include a fault switch 48 for momentarily disconnecting the battery pack 20 from the rest of the vehicle's electrical components in the event of a fault.

[0046] Reference Figure 1 The controller C is adapted to selectively execute one or more modes 50 for controlling the operation of the electric vehicle 12. The controller C is adapted to modify the corresponding positions of the switches S during the execution of various input signals in response to various input signals. Table 1 below shows the corresponding positions of the first set of switches (SA1, SA2) and the second set of switches (SB1, SB2) during various operating conditions of the electric vehicle 12.

[0047] Table 1

[0048] Condition / Switch SA1 SA2 SB1 SB2 Car charger closure disconnect disconnect disconnect disconnect disconnect start up disconnect disconnect Connect Connect Connect Promote operation Connect Connect disconnect disconnect disconnect Cabin adjustment disconnect disconnect disconnect disconnect Connect DC fast charging Connect Connect Connect Connect Connect AC charging Connect Connect disconnect disconnect Connect

[0049] Mode 50 includes a first mode 100 (off), a second mode 200 (start), a third mode 300 (propulsion operation and cabin adjustment), a fourth mode 400 (DC charging), and a fifth mode 500 (AC charging). These modes are described below for... Figure 2-5 Describe it. Figure 1 Each of the modes in mode 50 can be embodied as computer-readable code or instructions, which are stored in Figure 1 The controller C is partially available from... Figure 1The controller C executes the commands. It is understood that modes 50 are independent of each other. Modes 50 do not need to be applied in the specific order described herein. Furthermore, it should be understood that some steps can be eliminated.

[0050] Mode 50 can be executed dynamically. As used herein, the terms 'dynamic' and 'dynamically' describe steps or processes executed in real time, and are characterized by monitoring or otherwise determining the state of parameters during the execution of the routine or between iterations of the routine's execution and updating the state of the parameters periodically or periodically.

[0051] Now refer to Figure 2 Stored Figure 1 On the controller C and can be controlled by Figure 1 The flowcharts of the first mode 100 and the second mode 200 executed by the controller C are shown. The first mode 100 is executed during the off condition or mode of the electric vehicle 12. The second mode 200 is executed during the start condition or mode. The execution of the first mode 100 and the second mode 200 begins at block 202, where the controller C is adapted to verify that the first set of switches (SA1, SA2) and the second set of switches (SB1, SB2) are turned off (disconnected) and the wake-up operation is completed.

[0052] Proceeding to block 204, controller C adapts to determine if a charging mode is requested. If a charging mode is requested (block 204 = "Yes"), controller C proceeds to block 206 to determine if an AC charging mode is requested. If an AC charging mode is requested (block 206 = "Yes"), then mode 500 (see...) Figure 5 The process is executed. If the AC charging mode is not requested (block 206 = "No"), controller C proceeds to block 208 to determine if the DC charging mode is requested. If the DC charging mode is requested (block 208 = "Yes"), then the fourth mode 400 (see...) is executed. Figure 4 The first mode 100 is executed if the DC charging mode is not requested (block 208 = "No"). The loop returns.

[0053] Reference Figure 2 If the charging mode is not requested (block 204 = "No"), controller C proceeds to block 210 to determine if the propulsion mode is requested. If the propulsion mode is requested (block 210 = "Yes"), then the third mode 300 (see...) Figure 3 The process is executed. If the advance mode is not requested (block 210 = "No"), controller C proceeds to block 212 to determine if the attachment mode is requested. If the attachment mode is requested (block 212 = "Yes"), then the third mode 300 (see...) is executed. Figure 3The first mode 100 is executed if the attachment mode is not requested (block 212 = "No"). The first mode 100 is re-executed (loop returns).

[0054] Now refer to Figure 3 Stored Figure 1 On the controller C and can be controlled by Figure 1 A flowchart of the third mode 300 executed by the controller C is shown. The execution of the third mode 300 begins at block 302, where the controller C is adapted to verify that the first set of switches (SA1, SA2) and the second set of switches (SB1, SB2) are turned off (disconnected) and the charging port 34 is unplugged or disconnected.

[0055] Next, proceeding to block 304, controller C adapts to close the second set of switches (SB1, SB2) and enable the on-board charger 32, so that the output current is set to a predefined allowable pre-charge current (I0). out =I precharge Output voltage limit (V) out The voltage (V) of battery pack 20 is set to the battery voltage of battery pack 20. batt According to block 306, controller C adapts to wait until the bus voltage across the push HV bus is within a predefined increment (ΔV) of the battery voltage, and then closes (turns on) the first set of switches (SA1, SA2). In other words, controller C adapts to wait until V bus and V batt The absolute value of the difference is less than ΔV(|V bus -V batt |<ΔV). It is understood that the predefined allowable precharge current and the predefined increment value may vary based on the application at hand.

[0056] Proceeding to block 308, controller C is adapted to disable the on-board charger 32 and turn off (disconnect) the second set of switches (SB1, SB2). Proceeding to block 310, controller C is adapted to set a propulsion command in response to the torque demand of the electric vehicle 12. When propulsion ends, according to block 312, controller C can be adapted to redirect to either the first mode 100 or the second mode 200 based on whether the shutdown condition is met.

[0057] Now refer to Figure 4 Stored Figure 1 On the controller C and can be controlled by Figure 1 A flowchart of the fourth mode 400 executed by the controller C is shown. The execution of the fourth mode 400 begins at block 402, where the controller C is adapted to verify that the first set of switches (SA1, SA2) and the second set of switches (SB1, SB2) are turned off (disconnected) and the on-board charger 32 is connected to the charging port 34.

[0058] Proceeding to block 404, controller C adapts to command on-board charger 32 to apply a voltage equal to the battery voltage and activate on-board charger 32, such that the output current is set to a predefined allowable precharge current. The output voltage limit is set to the battery voltage of battery pack 20. Following block 406, controller C adapts to wait until the bus voltage across the push HV bus is within a predefined increment (ΔV) of the battery voltage (V0). bus -V batt <ΔV), then close (connect) the first set of switches (SA1, SA2).

[0059] Proceeding to block 408, controller C is adapted to disable the on-board charger 32 and close (turn on) the second set of switches (SB1, SB2). Proceeding to block 410, controller C is adapted to request DC charging current via the DC fast charging HV bus (see 42A, 42B). When charging is complete, according to block 412, controller C is adapted to turn off (disconnect) the second set of switches (SB1, SB2) and redirect to either mode 100 or mode 200.

[0060] Now refer to Figure 5 Stored Figure 1 On the controller C and can be controlled by Figure 1 A flowchart of the fifth mode 500 executed by the controller C is shown. The execution of the fifth mode 500 begins at block 502, where the controller C is adapted to verify that the first set of switches (SA1, SA2) and the second set of switches (SB1, SB2) are turned off (disconnected) and the on-board charger 32 is connected to the charging port 34.

[0061] Proceeding to block 504, controller C is adapted to enable onboard charger 32, and the output current is set to a predefined allowable precharge current (I0). out =I precharge Output voltage limit (V) out The voltage (V) of battery pack 20 is set to the battery voltage of battery pack 20. batt According to block 506, controller C adapts to wait until the bus voltage across the push HV bus is within the predefined increment value (ΔV) of the battery voltage, and then closes (turns on) the first set of switches (SA1, SA2).

[0062] Proceed to block 508, where controller C adapts to restore onboard charger 32 to standby mode. Proceed to block 510, where controller C adapts to... Figure 1 The connections L1 and L2 shown request AC charging current. When AC charging is complete, according to block 512, controller C can be adapted to disable the on-board charger 32, turn off the first set of switches (SA1, SA2), and redirect to either the first mode 100 or the second mode 200.

[0063] In summary, system 10 enables pre-charging of the high-voltage bus 16 during propulsion or charging start-up operations. When pre-charging is enabled, a second set of switches (SB1, SB2) is closed to connect the charger input of the on-board charger 32 to the battery pack 20, and the charger output is commanded to ramp up using a constant current charge from the capacitors on the high-voltage bus 16. Alternatively, a ramp output voltage command can be used on-board charger 32 to gradually increase the bus voltage until it matches the battery voltage. In some embodiments, on-board charger 32 may be adapted to bypass or disable its power factor correction (PFC) stage during DC fast charging mode. The power factor can be corrected using a filtering process during the PFC stage. On-board charger 32 may have a single-stage or two-stage power conversion type. On-board charger 32 can also be used to diagnose the high-voltage bus capacitors from the voltage rise rate at a constant charging current during pre-charging operations.

[0064] Various components of System 10 are adaptable to communicate via a wireless network (not shown). The wireless network can be a wireless local area network (LAN) that links multiple devices using a wireless distribution method, a wireless metropolitan area network (MAN) that connects several wireless LANs, or a wireless wide area network (WAN) that covers a large area (such as neighboring towns and cities). The wireless network can be: WIFI or Bluetooth. TM A connection is defined as short-range radio (or wireless) technology designed to simplify communication within and between internet-connected devices and the internet. Other types of connections may be employed.

[0065] Figure 1The controller C may be a component of other controllers of the electric vehicle 12 or a separate module operatively connected to other controllers of the electric vehicle 12. The controller C includes a computer-readable medium (also referred to as a processor-readable medium), which includes non-transitory (e.g., tangible) media involved in providing data (e.g., instructions) that can be read by a computer (e.g., by a computer's processor). Such media may take many forms, including but not limited to non-volatile and volatile media. Non-volatile media may include, for example, optical discs or magnetic disks and other permanent storage. Volatile media may include, for example, dynamic random access memory (DRAM), which may constitute main memory. Such instructions may be transmitted by one or more transmission media, including coaxial cables, copper wires, and optical fibers, including conductors that include a system bus coupled to a computer's processor. Some forms of computer-readable media include, for example, floppy disks, flexible disks, hard disks, magnetic tapes, other magnetic media, CD-ROMs, DVDs, other optical media, physical media with a pattern of holes, RAM, PROMs, EPROMs, FLASH-EEPROMs, other storage chips or cartridges, or other media that a computer can read.

[0066] The query tables, databases, data repositories, or other data warehouses described herein can include various mechanisms for storing, accessing, and retrieving various types of data, including hierarchical databases, a set of files in a file system, application databases in proprietary formats, relational database management systems (RDBMS), etc. Each such data warehouse can be contained within a computing device employing a computer operating system (such as one of the aforementioned operating systems) and can be accessed via a network in one or more of various ways. File systems are accessible from the computer operating system and can include files stored in various formats. In addition to languages ​​used for creating, storing, editing, and executing stored procedures, RDBMS can also employ Structured Query Language (SQL), such as the PL / SQL language described above.

[0067] The flowcharts illustrated illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this disclosure. In this respect, each block in a flowchart or block diagram may represent a module, segment, or portion of code comprising one or more executable instructions for implementing one or more specified logical functions. It will also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, may be implemented by a system based on dedicated hardware or a combination of dedicated hardware and computer instructions that performs the specified functions or actions. These computer program instructions may also be stored in a computer-readable medium capable of directing a controller or other programmable data processing device to operate in a particular manner, such that the instructions stored in the computer-readable medium produce an article of writing comprising instructions to implement the functions / actions specified in the blocks of the plurality of flowcharts and / or block diagrams.

[0068] Numerical values ​​of parameters (e.g., quantities or conditions) in this specification, including the appended claims, should be understood to be modified by the term "about" in each respective instance, regardless of whether the term "about" actually appears before the numerical value. "About" indicates that the stated numerical value allows for some slight imprecision (close to correctness on the value; approximately the value or reasonably close to the value; almost). If this general meaning is not utilized in the art to otherwise understand the imprecision provided by "about," then the "about" indication as used herein can at least arise from variations in common methods of measuring and using such parameters. Furthermore, the disclosure of ranges includes the disclosure of each value throughout the range and further subdivisions of the range. Each value within the range and the endpoints of the range are therefore disclosed as separate embodiments.

[0069] Detailed description and accompanying drawings or figures support and describe this disclosure, but the scope of this disclosure is defined only by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for implementing this disclosure as defined in the appended claims. Furthermore, features of the embodiments shown in the drawings or the various embodiments mentioned in this description are not necessarily to be construed as independent embodiments. Rather, it is possible that each feature described in one example of an embodiment can be combined with one or more other contemplated features from other embodiments, resulting in other embodiments not described in words or with reference to the drawings. Therefore, such other embodiments fall within the framework of the appended claims.

Claims

1. A system for controlling the starting operation of an electric vehicle, the system comprising: A high-voltage electric propulsion unit includes at least one battery pack, a high-voltage bus, one or more power components, a first set of switches, and a second set of switches. An on-board charger adapted to deliver an adjustable current to precharge the high-voltage bus during the startup operation; The charging port is directly coupled to the input of the vehicle charger; A controller, in communication with the on-board charger, has a processor and a tangible non-transitory memory thereon for recording instructions to selectively execute one or more modes; The first set of switches selectively connects the at least one battery pack to the push high voltage (HV) bus, and the second set of switches selectively connects the at least one battery pack to the charging port high voltage (HV) bus. and The controller is adapted to control the operation of the first set of switches and the second set of switches so as to enable pre-charging of the high-voltage bus during the startup operation.

2. The system of claim 1, wherein the electric vehicle is defined by the absence of a dedicated pre-charging circuit for the startup operation of the high-voltage bus.

3. The system of claim 1, wherein the one or more power components include an accessory power module and at least one power inverter module.

4. The system of claim 1, wherein the vehicle charger is adapted to operate according to a DC input voltage and an AC input voltage from the charging port.

5. The system of claim 1, wherein the on-board charger is configured to allow bidirectional current flow.

6. The system of claim 1, wherein: The first set of switches selectively connects the DC output of the on-board charger to the at least one battery pack; The first set of switches selectively disconnects at least one battery pack from the propulsion HV bus; and The second set of switches is adapted to isolate the charging port and the charging port HV bus from the at least one battery pack when the electric vehicle is turned off or in driving mode.

7. The system of claim 6, wherein The controller is adapted to enable the on-board charger by setting the output current of the on-board charger to a predefined allowable pre-charge current and setting the output voltage limit of the on-board charger to the battery voltage of the at least one battery pack.

8. The system of claim 7, wherein the one or more modes include a propulsion mode, and execution of the propulsion mode includes: Verify that the first set of switches and the second set of switches are off and that the charging port is unplugged; Close the second set of switches and activate the vehicle charger; When the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage, the first set of switches is closed; and Disable the on-board charger, turn off the second set of switches, and set the propulsion command.

9. The system of claim 7, wherein the one or more modes include a direct current (DC) charging mode, and the execution of the DC charging mode includes: Verify that the first set of switches and the second set of switches are off and that the vehicle charger is connected to the charging port; The charger is commanded to apply a voltage equal to the battery voltage, and the on-board charger is activated. When the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage, the first set of switches is closed; and Disable the on-board charger, close the second set of switches, and request DC charging current from the external charger.

10. The system of claim 7, wherein the one or more modes include an AC charging mode, and the execution of the AC charging mode includes: Verify that the first set of switches and the second set of switches are off and that the vehicle charger is connected to the charging port; The charger is commanded to apply a voltage equal to the battery voltage, and the on-board charger is activated. When the bus voltage across the propulsion HV bus is within a predefined increment value of the battery voltage, the first set of switches is closed; and Return the vehicle charger to standby mode and request AC charging current.

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