Vehicle-to-load (V2L) power using a bidirectional on-board charger (OBC)
By using a two-way on-board charger (OBC) in electric work vehicles, external AC power is converted to DC and then back to AC, solving the problem of the lack of high-power AC sockets in electric work vehicles. This achieves flexible power supply and efficient power conversion, supports single-phase and three-phase power output, and meets the needs of different equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- INT TRUCK INTPROP CO LLC
- Filing Date
- 2025-12-16
- Publication Date
- 2026-06-16
AI Technical Summary
Existing technology makes it difficult to provide high-power AC sockets for electric work vehicles, resulting in the need for expensive, self-contained equipment that requires refueling.
It adopts a two-way on-board charger (OBC), which includes a converter and an inverter. It can convert external AC power into DC power and store it in a high-voltage battery, and convert DC power into AC power to supply external devices. It supports single-phase and three-phase charging and provides up to 80 amps of single-phase and 32 amps of three-phase power through the power socket.
It provides flexible power supply options to support the charging and operation of both low-power and high-power devices, reducing reliance on expensive self-contained equipment and improving the flexibility and efficiency of power supply for electric work vehicles.
Smart Images
Figure CN122211240A_ABST
Abstract
Description
Technical Field
[0001] This disclosure generally relates to electric vehicles (EVs), and more specifically to vehicle-to-load (V2L) power systems using a bidirectional on-board charger (OBC). Background Technology
[0002] Typically, drivers and operators of work vehicles use high-powered tools or equipment such as tools for welding, cutting, and drilling, air compressors, saws, etc. EV work vehicles do not offer AC outlets that can provide high-power output (such as 5 kilowatts (kW) or more). Current technologies for powering these tools and equipment include: directly connecting power tools using an AC outlet, field generators, or providing the functionality of tools (e.g., air compressors), as well as standalone self-contained devices that integrate both a generator and battery. Unfortunately, these self-contained accessories are extremely expensive and require refueling. Improved technologies are needed to power high-powered power tools and equipment. Summary of the Invention
[0003] According to one aspect of this disclosure, a vehicle is provided. The vehicle includes: an electric motor for moving the vehicle; a high-voltage (HV) battery that supplies power to the electric motor to move the vehicle; a charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; an electrical outlet configured to supply electrical power to an external device; and an on-board charger (OBC) electrically coupled to the electrical outlet, the HV battery, and the charging port. The OBC includes: a converter configured to convert the first AC power received from the external AC power source into first DC power and supply the first DC power to the HV battery; and an inverter configured to receive second DC power from the HV battery and convert the second DC power into second AC power, which is supplied to the external device when the external device is electrically connected to the electrical outlet.
[0004] In one embodiment, the OBC is bidirectional. In another embodiment, the converter includes: a single-phase and three-phase compatible power factor correction (PFC) circuit; and an inductor-inductor-capacitor (LLC) resonant converter configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery. In another embodiment, the external device is electrically connected to the electrical outlet via a jack inserted into the electrical outlet, and the jack is fixed to the vehicle. In another embodiment, the vehicle further includes: a user interface and a controller electrically coupled to the OBC. In another embodiment, the controller is configured to switch between single-phase charging and three-phase charging based on user input from the user interface.
[0005] In another embodiment of the aspect, the controller is configured to automatically stop charging the electrical equipment when the HV battery is at or below a predetermined power threshold based on user input from the user interface. In another embodiment of the aspect, the controller is configured to enable and disable the inverter based on user input from the user interface. In another embodiment of the aspect, the electrical outlet is configured to output: up to 80 amps per phase for 120 Vac single-phase; 240 Vac for split-phase; and up to 32 amps per phase for 208 Vac three-phase.
[0006] According to another aspect, a vehicle is provided. The vehicle includes: an electric motor that moves the vehicle; a high-voltage (HV) battery that supplies power to the electric motor to move the vehicle; a charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; an electrical outlet configured to supply electrical power to an external device; and an on-board charger (OBC) electrically coupled to the electrical outlet, the HV battery, and the charging port. The OBC is bidirectional and has: a converter configured to convert the first AC power received from the external AC power source into first DC power and to supply the first DC power to the HV battery, the converter having: a single-phase and three-phase compatible power factor correction (PFC) circuit, and an inductor-inductor-capacitor (LLC) resonant converter configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery; and an inverter configured to receive second DC power from the HV battery and to convert the second DC power into second AC power, the second AC power being supplied to the external device when the external device is electrically connected to the electrical outlet.
[0007] In an embodiment of this aspect, the external device is electrically connected to the electrical outlet via a socket inserted into the outlet, and the socket is fixed to the vehicle. In another embodiment of this aspect, the vehicle further includes a user interface and a controller electrically coupled to the OBC. In yet another embodiment of this aspect, the controller is configured to switch between single-phase charging and three-phase charging based on user input from the user interface. In another embodiment of this aspect, the controller is configured to automatically stop charging the electrical device when the HV battery is at or below a predetermined power threshold based on user input from the user interface. In another embodiment of this aspect, the controller is configured to enable and disable the inverter based on user input from the user interface. In yet another embodiment of this aspect, the electrical outlet is configured to output: up to 80 amps per phase for 120 Vac single-phase; 240 Vac for split-phase; and up to 32 amps per phase for 208 Vac three-phase.
[0008] According to another aspect, a vehicle is provided. The vehicle includes: an electric motor that moves the vehicle; a high-voltage (HV) battery that supplies power to the electric motor to move the vehicle; a charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; an electrical outlet configured to supply electrical power to an external device; and an on-board charger (OBC) electrically coupled to the electrical outlet, the HV battery, and the charging port. The OBC is bidirectional and has: a converter configured to convert the first AC power received from the external AC power source into first DC power and supply the first DC power to the HV battery, the converter having: a single-phase and three-phase compatible power factor correction (PFC) circuit, and an inductor-inductor-capacitor (LLC) resonant converter configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery; and an inverter configured to receive second DC power from the HV battery and convert the second DC power into second AC power, the second AC power being supplied to the external device when the external device is electrically connected to the electrical outlet.
[0009] In an embodiment of this aspect, the external device is electrically connected to the electrical outlet via a socket inserted into the outlet. In another embodiment of this aspect, the socket is fixed to the vehicle. In yet another embodiment of this aspect, the vehicle further includes a user interface and a controller electrically coupled to the OBC, the controller being configured to switch between single-phase charging and three-phase charging based on user input from the user interface, and the controller being configured to enable and disable the inverter based on user input from the user interface. Attached Figure Description
[0010] The foregoing and other features of this disclosure will become apparent from the following description, the appended claims, and the accompanying drawings. These drawings depict only a few embodiments according to this disclosure and should not be construed as limiting its scope.
[0011] Figure 1 This is a schematic diagram of a system according to an embodiment of the present disclosure;
[0012] Figure 2 This is a block diagram of a system according to another embodiment of the present disclosure;
[0013] Figure 3 These are circuit diagrams according to embodiments of the present disclosure; and
[0014] Figure 4 This is a block diagram of a system according to yet another embodiment of the present disclosure.
[0015] In the detailed description below, various embodiments are described with reference to the accompanying drawings. Those skilled in the art will understand that the drawings are schematic and simplified for clarity. Throughout the text, similar reference numerals refer to similar elements or parts. Therefore, similar elements or parts are not necessarily described in detail in every drawing. Detailed Implementation
[0016] As mentioned above, there is a need for improved technologies to supply power to high-power power tools and equipment. This disclosure provides an arrangement for outputting AC from a bidirectional on-board charger (OBC). In some embodiments, the OBC allows an assembler to install a socket / socket in the vehicle or install a custom AC solution as needed. This OBC is a bidirectional OBC, where the common port can accommodate single-phase or three-phase charging. Therefore, by utilizing the EV potential to output AC, low-power household electrical appliances and high-power electrical appliances can be charged and operated in the EV. The common port or electrical socket can provide the following output: for 120 V ac Single-phase, up to 80 amps (A) per phase; 240 Vac for split-phase; and up to 32 A per phase for 208 Vac three-phase. Single-phase / split-phase or three-phase can be software-configurable (automatic) to provide flexibility to the vehicle operator. The vehicle control system can prevent the high-voltage (HV) battery state of charge (SoC) from being too low (e.g., less than 20%, software-configurable). The human-machine interface (HMI) can allow the operator / user to selectively enable and disable electrical equipment charging features and can also be designed to provide feedback to the operator / user.
[0017] refer to Figure 1This document describes an example vehicle 100 according to embodiments of the present disclosure. The vehicle 100 includes: an electric motor 110 for moving the vehicle 100, an HV battery 112 that supplies power to the electric motor 110 to drive or move the vehicle 100, and a charging port 114. The charging port 114 is configured to receive AC power from an external AC power source (not shown) via a charging cable to charge the HV battery 112. The external AC power source may be a standard household wall outlet / socket (typically 120 V, Level 1 charging) or a charging station (Level 2 or Level 3 charging). Other AC power sources may also be used to charge the HV battery 112.
[0018] Vehicle 100 further includes an electrical socket 116 and an OBC 120. The electrical socket 116 is configured to supply electrical power to an external device (such as a high-power tool) when it is electrically connected. The external device can be electrically connected to the electrical socket 116 by inserting it into a jack (also referred to in the art as a socket).
[0019] For clarity, the term "electrical outlet" as used herein refers to a point in a wiring system from which current is drawn to supply power to equipment in use; in other words, it is a location from which power is drawn to supply power to external devices. The term "receptacle" refers to the contact device installed at an electrical outlet for connecting a plug; in other words, a receptacle is the physical part that receives the plug. Figure 3 A socket 118 is shown at electrical outlet 116. Alternative embodiments may use other types of known sockets. Socket 118 is fixed to vehicle 100 during vehicle manufacturing, or an assembler may customize vehicle 100 by installing socket 118 at electrical outlet 116, which is electrically coupled to a bidirectional OBC according to this disclosure.
[0020] refer to Figure 2 This document describes example diagrams of an OBC 120, an electrical socket 116, and their electrical connections according to embodiments of the present disclosure. An external device 122 (such as a high-power tool) can be inserted into the socket 118. The external device 122 includes a plug (not shown) at the end of a wire (not shown) shaped to mate with the female socket 118. The external device 122 can also be a low-power device. Advantageously, the OBC 120 circuitry is configured to supply single-phase / split-phase charging in addition to three-phase charging for more demanding loads.
[0021] An OBC (On-Board Charger) is a charger for the EV's electric motor battery that is located "on-board" within the EV, rather than being an "off-board" charger located outside the EV. OBCs are advantageous because they provide EV operators with the flexibility to charge the EV whenever any compatible electrical outlet is available. Furthermore, OBCs typically offer better voltage matching compared to off-board chargers, as they can be specifically designed to meet the specific voltage requirements of the battery inside the EV; while off-board chargers are generally designed to support a wide range of EV battery voltages. On the other hand, OBCs add to the EV's weight, and off-board chargers are more likely to be designed with converter systems that have very high power density for faster Level 3 charging.
[0022] For clarity, as used herein, the term "converter" refers to a circuit that converts AC power to DC power or performs DC-DC conversion. The term "inverter" refers to a circuit that converts DC power to AC power.
[0023] Refer again Figure 2 The OBC 120 is also electrically coupled to the HV battery 112 and the charging port 114. The OBC 120 is electrically coupled to the HV battery 112 via a DC bus 128 on which DC power is supplied to charge the HV battery 112. The OBC 120 has a converter 130 configured to convert AC power received (via charging cable 134) from an external AC power source 132 into DC power to charge the HV battery 112.
[0024] The OBC 120 is bidirectional. Therefore, in addition to charging the HV battery 112, the OBC 120 of this disclosure also includes an inverter 136 configured to receive DC power stored in the HV battery 112 via a DC bus 138 and convert the received DC power into AC power, which can be supplied to the external device 122 when it is electrically connected to the electrical outlet 116. The AC power output supplied to the electrical outlet 116 is: up to 80 amps (A) per phase for 120 Vac single-phase; up to 32 A per phase for split-phase 240 Vac; and up to 32 A per phase for 208 Vac three-phase.
[0025] Figure 3An example circuit diagram is shown. This diagram illustrates: a single-phase and three-phase compatible power factor correction (PFC) circuit 140; and an inductor-inductor-capacitor (LLC) resonant converter 142 (i.e., a full-bridge LLC resonant converter) configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of a specific HV battery in the vehicle. Advantageously, the circuit is configured to both charge the HV battery and convert DC to AC to charge external devices such as high-power tools.
[0026] In some embodiments, a human-machine interface (HMI) is provided to allow the EV operator / user to selectively switch between single-phase and three-phase charging, or to selectively enable and disable the inverter. The HMI can also be configured to automatically stop charging the electrical equipment when the HV battery's SoC reaches or falls below a power threshold selectable by the operator / user.
[0027] refer to Figure 4 This disclosure describes an example implementation of an HMI in vehicle 400. According to this disclosure, vehicle 400 includes a controller 402, a user interface 404, and a bidirectional OBC 420.
[0028] Controller 402 includes a communication interface 410 and a processing circuitry 412. Communication interface 410 is configured to establish and maintain wired or wireless connections with OBC 420 and user interface 404. Processing circuitry 412 includes memory 414 and one or more processors 416. Processing circuitry 412 and / or processors 416 may be, for example, a central processing unit (CPU), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), etc. Memory 414 may include any type of volatile and / or non-volatile memory, such as cache, buffer memory, random access memory (RAM), read-only memory (ROM), etc. Memory 414 includes OBC unit 218 having computer instructions that, when executed by processor 416, cause processor 416 to perform the methods and techniques described herein (such as allowing the EV operator / user to selectively switch between charging modes, setting SoC thresholds, enabling / disabling bidirectional charging of external devices, etc., as described herein).
[0029] refer to Figure 4User interface 404 may be, for example, a touchscreen computer that allows the user to input user information. User interface 404 includes a user input interface (IF) 430 (such as, for example, a touchscreen, keyboard, buttons, audio input interface (microphone), etc.). User interface 404 includes a user display 432 that displays information to the user (such as current SoC threshold, current charging mode, etc.). User interface 404 includes a communication interface (not shown) and a processing circuitry system 434. The communication interface is configured to establish and maintain a wired connection with OBC 420 and, possibly, establish and maintain a wireless connection with a wide area network (WAN) (such as the Internet) (e.g., a radio transceiver). Processing circuitry system 434 includes memory 436 and one or more processors 438. Processing circuitry system 434 and / or processor 438 may be, for example, a central processing unit (CPU), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), etc. Memory 436 may include any type of volatile and / or non-volatile memory, such as cache, buffer memory, random access memory (RAM), read-only memory (ROM), etc. Memory 436 includes a user unit 440 having computer instructions that, when executed by processor 438, cause processor 438 to perform the methods and techniques described herein.
[0030] User unit 440 in user interface 404 has computer instructions to cause processor 438 to receive and interpret user input from user input interface (IF) 430 and accordingly instruct controller 402. OBC unit 418 in controller 402 has computer instructions to cause processor 416 to switch OBC 420 between single-phase charging and three-phase charging based on user input from user interface 404. OBC unit 418 in controller 402 has computer instructions to cause processor 416 to automatically stop charging electrical equipment when the HV battery is at or below a predetermined power threshold based on user input from user interface 404. OBC unit 418 in controller 402 has computer instructions to cause processor 416 to enable and disable the inverter based on user input from user interface 404. Industrial applicability
[0031] A vehicle is disclosed, comprising: an electric motor for moving the vehicle; a high-voltage (HV) battery for supplying power to the electric motor to move the vehicle; a charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; an electrical outlet configured to supply electrical power to an external device; and an on-board charger (OBC) electrically coupled to the electrical outlet, the HV battery, and the charging port. The OBC includes: a converter configured to convert the first AC power received from the external AC power source into first DC power and configured to supply the first DC power to the HV battery; and an inverter configured to receive second DC power from the HV battery and configured to convert the second DC power into second AC power, the second AC power being supplied to the external device when the external device is electrically connected to the electrical outlet. This system can be manufactured industrially for use in consumer-purchased vehicles.
[0032] In view of the foregoing description, numerous modifications to the invention will be apparent to those skilled in the art. It is not intended to limit the invention to the exact constructions and operations shown and described; therefore, all suitable modifications and equivalents may be made, all falling within the scope of the invention. Consequently, this specification should be construed as merely illustrating the principles of the invention and is presented to enable those skilled in the art to make and use the invention and to teach the best mode of implementation. Exclusive rights to all modifications falling within the scope of the appended claims are reserved. All patents, patent publications, and patent applications cited herein, as well as other references, are incorporated herein by reference in their entirety.
Claims
1. A vehicle comprising: An electric motor that moves the vehicle; A high-voltage (HV) battery supplies power to the electric motor to move the vehicle; A charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; An electrical outlet configured to supply electrical power to external devices; as well as An on-board charger (OBC) electrically coupled to the electrical socket, the HV battery, and the charging port, the OBC comprising: A converter configured to convert the first AC power received from the external AC power source into first DC power and supply the first DC power to the HV battery; as well as An inverter configured to receive a second DC power from the HV battery and convert the second DC power into a second AC power, which is supplied to the external device when the external device is electrically connected to the electrical outlet.
2. The vehicle of claim 1, wherein the OBC is bidirectional.
3. The vehicle of claim 2, wherein the converter comprises: Power factor correction (PFC) circuits compatible with both single-phase and three-phase operation; And an inductor-inductor-capacitor (LLC) resonant converter, configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery.
4. The vehicle of claim 1, wherein the external device is electrically connected to the electrical socket via a jack inserted into the electrical socket, and the jack is fixed to the vehicle.
5. The vehicle as claimed in claim 1, further comprising: The user interface and the controller electrically coupled to the OBC.
6. The vehicle of claim 5, wherein the controller is configured to switch between single-phase charging and three-phase charging based on user input from the user interface.
7. The vehicle of claim 5, wherein the controller is configured to automatically stop charging the electrical equipment when the HV battery is at or below a predetermined power threshold based on user input from the user interface.
8. The vehicle of claim 5, wherein the controller is configured to enable and disable the inverter based on user input from the user interface.
9. The vehicle of claim 1, wherein the electrical socket is configured to output: For a 120 Vac single-phase power supply, each phase can deliver up to 80 amperes. For phase 240 Vac; and For a 208 Vac three-phase system, each phase delivers up to 32 amperes.
10. A vehicle comprising: An electric motor that moves the vehicle; A high-voltage (HV) battery supplies power to the electric motor to move the vehicle; A charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; An electrical outlet configured to supply electrical power to external devices; as well as An on-board charger (OBC) electrically coupled to the electrical socket, the HV battery, and the charging port, the OBC being bidirectional and comprising: A converter configured to convert first AC power received from the external AC power source into first DC power and supply the first DC power to the HV battery, the converter having: a single-phase and three-phase compatible power factor correction (PFC) circuit and an inductor-inductor-capacitor (LLC) resonant converter configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery. as well as An inverter configured to receive a second DC power from the HV battery and convert the second DC power into a second AC power, which is supplied to the external device when the external device is electrically connected to the electrical outlet.
11. The vehicle of claim 10, wherein the external device is electrically connected to the electrical socket via a jack inserted into the electrical socket, and the jack is fixed to the vehicle.
12. The vehicle of claim 10, further comprising: The user interface and the controller electrically coupled to the OBC.
13. The vehicle of claim 12, wherein the controller is configured to switch between single-phase charging and three-phase charging based on user input from the user interface.
14. The vehicle of claim 12, wherein the controller is configured to automatically stop charging the electrical equipment when the HV battery is at or below a predetermined power threshold based on user input from the user interface.
15. The vehicle of claim 12, wherein the controller is configured to enable and disable the inverter based on user input from the user interface.
16. The vehicle of claim 10, wherein the electrical socket is configured to output: For a 120 Vac single-phase power supply, each phase can deliver up to 80 amperes. For phase 240 Vac; and For a 208 Vac three-phase system, each phase delivers up to 32 amperes.
17. A vehicle comprising: An electric motor that moves the vehicle; A high-voltage (HV) battery supplies power to the electric motor to move the vehicle; A charging port configured to receive first AC power from an external AC power source via a charging cable to charge the HV battery; An electrical outlet configured to supply electrical power to external devices; as well as An on-board charger (OBC) electrically coupled to the electrical socket, the HV battery, and the charging port, the OBC being bidirectional and comprising: A converter configured to convert first AC power received from the external AC power source into first DC power and supply the first DC power to the HV battery, the converter having: a single-phase and three-phase compatible power factor correction (PFC) circuit and an inductor-inductor-capacitor (LLC) resonant converter configured to stabilize the output voltage of the PFC circuit based on the voltage requirements of the HV battery. as well as An inverter configured to receive a second DC power from the HV battery and convert the second DC power into a second AC power, which is supplied to the external device when the external device is electrically connected to the electrical outlet.
18. The vehicle of claim 17, wherein the external device is electrically connected to the electrical socket via a jack inserted into the electrical socket.
19. The vehicle of claim 18, wherein the jack is secured to the vehicle.
20. The vehicle of claim 17, further comprising: A user interface and a controller electrically coupled to the OBC, the controller being configured to switch between single-phase charging and three-phase charging based on user input from the user interface and to enable and disable the inverter based on user input from the user interface.