Power control system with power distributor

Abstract

This invention relates to a power control system with a power distributor. A power control system and method are provided for supplying power from a first power source to a socket while a battery is being charged by the first power source. The first power source transmits power at a predetermined voltage and phase to an on-board charging control module, which regulates the power to charge the battery. The power control system includes a third inverter configured to transmit power directly from the first power source to the socket in one of a plurality of phases. The system may also include a rectifier, a first inverter, and a second inverter. The rectifier is coupled to the first power source and transmits power from the first power source to the third inverter. The first and second inverters are configured to charge the battery with direct current (DC).

Description

[0001] The information provided in this section is for the purpose of generally presenting the context of this disclosure. Within the scope described in this section, the work of the currently named inventors and aspects of this description that may otherwise not conform to the prior art at the time of submission are neither expressly nor implicitly acknowledged as conflicting with the prior art of this disclosure. Technical Field

[0002] This disclosure generally relates to a power distribution system for simultaneously charging a battery and supplying power to an outlet. For example, electric vehicles include batteries for powering an electric motor to drive the vehicle, and vehicle electrical components such as a head unit, lights, and air conditioning systems. Some electric vehicles include outlets that vehicle occupants can use to power electrical devices such as, for example, cellular phones, tablets, and laptops. However, such outlets are typically not powered when the battery is being charged from a residential outlet or a commercial power station. Background Technology

[0003] Electric vehicles also include an inlet for receiving power from a charger coupled to an electric utility station or a residential home. The inlet can be configured to receive 120 volts or 240 volts of alternating current (“AC”), and the voltage can be delivered in different phases.

[0004] Therefore, it is desirable to have a power distribution system in which the outlet is operable to distribute power while the battery is charging. It is also desirable to simplify the conventional configurations associated with outlets. Furthermore, it is desirable to adjust the waveform and voltage of the power to suit the outlet to which the battery and / or electrical equipment will be coupled. Finally, it is desirable to overcome the problems associated with charging batteries in cold conditions. Summary of the Invention

[0005] One aspect of this disclosure provides a power control system for use in an electric vehicle and configured to supply power to a socket and a battery. The battery is configured to power a motor configured to drive the electric vehicle. The power control system is configured to supply power from a first power source to the socket and the battery. The power control system includes an on-board charger module. The on-board charger module includes a first inverter, a second inverter, a winding machine, a rectifier, and a first processing unit. The first processing unit is configured to process power from the first power source to charge the battery. The first processing unit includes non-volatile memory storing written instructions for executing the on-board charger module. The first inverter, the winding machine, and the second inverter are configured to transfer power from the first power source to the battery, and the rectifier is configured to convert alternating current (AC) from the first power source into direct current (DC). The power control system also includes a third inverter, a first switch, and a second switch. The third inverter is electrically coupled to the rectifier and the first inverter. The first switch is inserted between the battery and the first inverter, and the second switch is inserted between the battery and the second inverter. The first processing unit is also configured to keep the first and second switches in the off position when the battery is being charged, to provide electrical isolation between the battery and the third inverter while the battery is being charged, and the third inverter converts the DC power from the rectifier into AC power. The AC power is then transmitted to a socket to allow power to the load while the battery is charging.

[0006] Embodiments of this disclosure may include one or more of the following optional features. In some embodiments, a first switch is inserted between the battery and the second inverter, and a second switch is inserted between the battery and the first inverter.

[0007] In some implementations, the power control system further includes a positive contact switch and a negative contact switch. The positive contact switch is inserted between the positive terminal of the battery and the second inverter, and the negative contact switch is inserted between the negative terminal of the battery and the second inverter.

[0008] In some implementations, the third inverter may be configured to supply voltage to a single-phase socket. Alternatively or additionally, the third inverter may be configured to supply voltage to at least two-phase sockets.

[0009] In some embodiments, the power control system may further include an auxiliary power module, a heater, and sensors. A rectifier may be configured to make the voltage and current of the first power supply in phase with the voltage and current of the battery. Sensors are configured to detect the temperature of the battery. The on-board charger module may also be configured to disconnect the first and second switches and close the positive and negative contact switches when the voltage and current of the first power supply are in phase with the voltage and current of the battery and the battery temperature is above a predetermined threshold. The on-board charger module may also be configured to disconnect the positive and negative contact switches when the battery temperature is equal to or below the predetermined threshold. The on-board charger module may also be configured to close the first and second switches when the battery supplies power to the motor.

[0010] Another aspect of this disclosure is a method for charging a battery of an electric vehicle while simultaneously supplying power from a first power source to a socket. The battery is configured to power a motor driving the electric vehicle. The method includes the step of providing an on-board charger module configured to process power from the first power source to charge the battery. The on-board charger module includes a first inverter, a second inverter, a winding machine, and a rectifier. The rectifier converts power from alternating current (AC) to direct current (DC). The first inverter converts DC to AC and transmits the AC to the winding machine. The winding machine transmits the AC to the second inverter. The second inverter converts AC to DC and transmits the DC to the battery to charge it. The method includes the step of providing a third inverter electrically coupled to the rectifier and configured to convert DC from the rectifier back to AC and transmit the AC to an output terminal while the battery is being charged.

[0011] In some implementations, the third inverter is configured to receive power in either single-phase or three-phase mode.

[0012] In some embodiments, the method may further include the step of providing a first switch and a second switch. The first switch is inserted between the battery and the second inverter, and the second switch is inserted between the battery and the first inverter. The method includes the step of keeping the first and second switches off while the battery is being charged to provide electrical isolation between the power supplied to the outlet and the battery during charging.

[0013] In some embodiments, the method further includes the step of providing a positive contact switch and a negative contact switch. The positive contact switch is inserted between the positive terminal of the battery and the second inverter, and the negative contact switch is inserted between the negative terminal of the battery and the second inverter. In such an embodiment, the method may include the steps of: aligning the voltage and current of a first power supply with the voltage and current of the battery; detecting the temperature of the battery, and closing the positive and negative contact switches when the battery temperature is above a predetermined threshold; and providing and turning on a heater to heat the battery when the battery temperature is below the predetermined threshold.

[0014] In some implementations, the method may include the step of keeping the positive and negative contact switches in the open position until the battery temperature is equal to or higher than a predetermined threshold.

[0015] In some implementations, the method may include the step of closing a first switch and a second switch when the battery supplies power to the motor.

[0016] In some implementations, the third inverter is configured to increase and decrease the voltage of the power supply.

[0017] This invention includes the following technical solutions:

[0018] 1. A power control system for supplying power to a socket and a battery, the battery being configured to power a motor, the power control system supplying the power from a first power source to the socket and the battery, the power control system comprising:

[0019] An on-board charger module includes a first processing unit configured to process power from a first power source to charge the battery. The first processing unit includes a non-volatile memory storing written instructions for executing the on-board charger module. The on-board charger module includes a first inverter, a second inverter, a winding machine, and a rectifier, wherein the first inverter, the winding machine, and the second inverter are configured to transmit power from the first power source to the battery, and the rectifier is configured to convert alternating current (AC) from the first power source into direct current (DC).

[0020] A third inverter is electrically coupled to the rectifier and the first inverter;

[0021] A first switch is inserted between the battery and the first inverter;

[0022] A second switch, which is inserted between the battery and the second inverter; and

[0023] The first processing unit is further configured to keep the first switch and the second switch in the off position when the battery is being charged, so as to provide electrical isolation between the battery and the third inverter when the battery is being charged, while the third inverter converts the DC power from the rectifier into AC power and supplies the AC power to the socket to allow power to the load when the battery is being charged.

[0024] 2. The power control system according to Scheme 1, wherein the first switch is inserted between the battery and the second inverter, and the second switch is inserted between the battery and the first inverter.

[0025] 3. The power control system according to Scheme 1 further includes a positive contact switch and a negative contact switch, wherein the positive contact switch is inserted between the positive terminal of the battery and the second inverter, and the negative contact switch is inserted between the negative terminal of the battery and the second inverter.

[0026] 4. The power control system according to Scheme 1, wherein the third inverter is configured to supply voltage to the socket in a single phase.

[0027] 5. The power control system according to Scheme 1, wherein the third inverter is configured to supply voltage to the socket in at least two phases.

[0028] 6. The power control system according to Scheme 3, wherein the rectifier is further configured to make the voltage and current of the first power supply in phase with the voltage and current of the battery.

[0029] 7. The power control system according to claim 6 further includes a heater and a sensor for detecting the temperature of the battery.

[0030] 8. The power control system according to Scheme 7, wherein the on-board charger module is further configured to disconnect the first switch and the second switch, and close the positive contact switch and the negative contact switch when the voltage and current of the first power supply are in phase with the voltage and current of the battery and the temperature of the battery is higher than a predetermined threshold.

[0031] 9. The power control system according to claim 8, wherein the on-board charger module is further configured to disconnect the positive contact switch and the negative contact switch when the temperature of the battery is equal to or lower than the predetermined threshold.

[0032] 10. The power control system according to claim 9, wherein the on-board charger module is further configured to close the first switch and the second switch when the battery supplies power to the motor.

[0033] 11. A method for simultaneously supplying power from a first power source to a socket and charging a battery of an electric vehicle, the battery being configured to power a motor configured to drive the electric vehicle, the method comprising the steps of:

[0034] An on-board charger module is provided, configured to process power from a first power source to charge a battery. The on-board charger module includes a first inverter, a second inverter, a winding machine, and a rectifier. The rectifier converts the power from alternating current (AC) to direct current (DC). The first inverter converts the DC to AC and transmits the AC to the winding machine. The winding machine transmits the AC to the second inverter, which converts the AC to DC and transmits the DC to the battery to charge it.

[0035] A third inverter is provided, which is electrically coupled to the rectifier and configured to convert direct current from the rectifier into alternating current, and to transmit the alternating current to the socket when the battery is being charged.

[0036] 12. The method according to claim 11, wherein the third inverter is configured to receive the power in either single-phase or three-phase mode.

[0037] 13. The method of claim 11 further includes the step of providing a first switch and a second switch, wherein the first switch is inserted between the battery and the second inverter, and the second switch is inserted between the battery and the first inverter, and the first switch and the second switch are kept off when the battery is being charged to provide electrical isolation between the power transmitted to the socket and the battery during charging.

[0038] 14. The method according to claim 13 further includes the step of providing a positive contact switch and a negative contact switch, the positive contact switch being inserted between the positive terminal of the battery and the second inverter, and the negative contact switch being inserted between the negative terminal of the battery and the second inverter.

[0039] 15. The method according to claim 14 further includes the step of making the voltage and current of the first power source in phase with the voltage and current of the battery.

[0040] 16. The method according to claim 15 further includes the step of detecting the temperature of the battery and closing the positive contact switch and the negative contact switch when the temperature of the battery is higher than a predetermined threshold.

[0041] 17. The method of claim 16 further includes the step of providing a heater and turning on the heater to heat the battery when the temperature of the battery is below the predetermined threshold.

[0042] 18. The method according to claim 17 further includes the step of keeping the positive contact switch and the negative contact switch in the open position until the temperature of the battery is equal to or higher than the predetermined threshold.

[0043] 19. The method according to claim 18 further includes the step of closing the first switch and the second switch when the battery supplies power to the motor.

[0044] 20. The method according to claim 19, wherein the third inverter is configured to increase and decrease the voltage of the power. Attached Figure Description

[0045] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0046] Figure 1 This is a schematic diagram of a conventional power control system with sockets for supplying power to a load;

[0047] Figure 2 It is used for Figure 1 The diagram shows the hardware and electrical components of the socket;

[0048] Figure 3 This is a perspective view of the vehicle, showing the vehicle's electrical control system coupled to a primary power source.

[0049] Figure 4 yes Figure 1 The diagram shows a power control system that supplies phase voltages from a three-phase voltage source to the socket.

[0050] Figure 5 yes Figure 1 The diagram shows a power control system that supplies three-phase voltage from a three-phase voltage source to a socket.

[0051] Figure 6 yes Figure 1 The schematic diagram shown illustrates a power control system having a single-phase inverter configured to supply three-phase voltage from a three-phase voltage source to a socket; and

[0052] Figure 7 This diagram illustrates a method of charging the battery of an electric vehicle while simultaneously supplying power from a first power source to a socket.

[0053] Throughout the accompanying figures, the corresponding reference numerals indicate the relevant parts. Detailed Implementation

[0054] Example configurations will now be described more fully with reference to the accompanying drawings. The example configurations are provided so that this disclosure will be comprehensive 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 comprehensive understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the example configurations may be embodied in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of this disclosure.

[0055] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular articles “a,” “an,” and “the” used herein may also be intended to include plural forms. The terms “comprising,” “containing,” “including,” 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. Unless explicitly identified as the order of execution, the method steps, processes, and operations described herein should not be construed as necessarily requiring them to be performed in the specific order discussed or illustrated. Additional or alternative steps may be employed.

[0056] When an element or layer is referred to as "on another element or layer," "attached to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly located on, attached to, connected to, attached to, or coupled to the other element or layer, or there may be an intervening element or layer present. Conversely, when an element is referred to as "directly located on another element or layer," "directly attached to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intervening element or layer 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 related listed items.

[0057] In this document, the terms “first,” “second,” “third,” etc., may be used to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another. Unless the context explicitly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply a sequence or order. Therefore, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section without departing from the teachings of the example configuration.

[0058] 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: application-specific integrated circuits (ASICs); digital, analog, or mixed-signal analog / digital discrete circuits; digital, analog, or mixed-signal analog / digital integrated circuits; combinational logic circuits; field-programmable gate arrays (FPGAs); (shared, dedicated, or group) processors that execute code; (shared, dedicated, or group) memory that stores the code executed by the processor; other suitable hardware components that provide the described functionality; or combinations of some or all of the above, such as in a system-on-a-chip.

[0059] 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 that, in combination with additional processors, 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 that, in combination with additional memory, 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.

[0060] The apparatus and methods described in this application can 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 and / or depend on stored data.

[0061] 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 game applications.

[0062] Non-transitory memory can be a physical device used to temporarily or permanently store 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., typically 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.

[0063] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and can be implemented using high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. 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.

[0064] Various implementations of the systems and techniques described herein can be implemented in 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 may include implementations in one or more computer programs that can be executed and / or interpreted on a programmable system including at least one programmable processor, which may be dedicated or general-purpose, coupled to receive and transmit data and instructions from a storage system, at least one input device, and at least one output device.

[0065] The processes and logic flows described in this specification can be implemented by one or more programmable processors (also known as data processing hardware) to execute one or more computer programs to perform functions by manipulating input data and generating output. The processes and logic flows can also be implemented by special-purpose logic circuitry, such as FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits). By way of example, processors suitable for executing computer programs include both general-purpose and special-purpose microprocessors, as well as any one or more processors of any type of digital computer. Generally, a processor receives instructions and data from read-only memory or random access memory, or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include one or more mass storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data or operatively coupled to receive data from or transfer data to, or both. However, a computer does not need to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, by way of 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 or incorporated therein by dedicated logic circuitry.

[0066] To provide interaction with the user, one or more aspects of this disclosure can be implemented on a computer with a display device, such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen for displaying information to the user, and optionally with a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides 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 acoustic, voice, or tactile input. Furthermore, the computer can interact with the user by sending and receiving documents to and from the device used by the user; for example, by sending a webpage to a web browser on the user's client device in response to a request received from a web browser.

[0067] Now for reference Figure 1This provides a conventional power control circuit 100 for an electric vehicle. The power control circuit 100 includes a battery 102, a first inverter 104, a second inverter 106, and a winding machine 108. The first inverter 104 and the second inverter 106 are electrically isolated from each other and can be powered by separate power modules and drivers. Each of the first inverter 104 and the second inverter 106 includes multiple transistors or MOSFETs suitable for switching between direct current (DC) and alternating current (AC). The winding machine 108 includes windings 108a-108f separated into two electrically isolated winding groups. Each winding group has its own neutral connection. The two winding groups share the same stator core and have the same rotor. The windings can be electromagnetically symmetrical about the winding machine 108 to avoid any imbalance, thereby increasing ease of control, etc., but in other configurations, they can be electromagnetically asymmetrical about the winding machine 108. The winding machine 108 can be a winding magnetic field synchronizer, a synchronous reluctance machine, etc.

[0068] First refer to Figure 1 The power control circuit 100 can be coupled to a first power source (not shown), such as a commercial charger or residential outlet, via a charging port 110. In one aspect, the charging port 110 may include high-voltage sockets for a DC (“DC”) port 112 and an AC (“AC”) port 114. A first inverter 104 can be coupled to the DC port 112, wherein a pair of DC switches 116 and 118 can be opened and closed to control the power supply to the first inverter 104. A front-end rectifier 120 is coupled to the AC port 114, wherein an AC switch 122 is opened and closed to control the power supply to the front-end rectifier 120.

[0069] Socket 124 is positioned between battery 102 and second inverter 106. Now refer to... Figure 2 The topology of socket 124 is provided, illustrating the hardware and electrical components. The hardware in socket 124 includes a filter 126 for filtering electromagnetic interference, a boost converter 128 for increasing power from battery 102, a resonant converter 130, a converter 132 for converting DC to AC, and a second filter 134 for filtering AC noise before it reaches socket 124. Such a topology increases the cost and complexity of the power control circuitry.

[0070] Furthermore, the battery's lifespan may deteriorate when charged in cold conditions. When a battery is cold, the chemical reactions within it slow down, which can lead to reduced charging capacity and potentially damage the battery. For example, if the battery is below freezing, the electrolyte may freeze and expand, causing an increase in electrolyte resistance, which in turn reduces charging efficiency and the battery's ability to retain charge.

[0071] Furthermore, the power source used to charge the battery may differ in voltage and waveform. For example, a commercial charging station may be configured to provide power with a higher voltage and a different phase compared to a residential power outlet.

[0072] This disclosure relates to a power control system 10 for simultaneously supplying power from a first power source 16 to a socket 12 and a battery 14, so that electrical equipment 18 can be powered by the socket 12 while the battery 14 is being charged. The power control system 10 can also be configured to provide electrical isolation between the battery 14 and the socket 12. In another aspect, the power control system 10 can be configured to execute a charging protocol to ensure that the battery 14 is at a desired temperature before charging. In yet another aspect, the power control system 10 is configured to increase or decrease the voltage from the first power source 16 to the socket 12. Still another aspect, the power control system is configured to change the phase of the power from the first power source 16 to the socket 12.

[0073] The first power source 16 can be a commercially developed charging station configured to provide 240 volts of power, or it can be a residential outlet configured to provide 120 volts of power. It should also be understood that the first power source 16 can be configured to provide power in DC form (e.g., a DC fast charging station) or in AC form. The power control system 10 can be implemented in any platform or device that uses battery 14 to power the device. For illustrative purposes, in... Figure 3 The power control system 10 is described in the context of the electric vehicle 20 shown. However, it should be understood that the power control system 10 can be implemented in other devices / platforms having a battery 14 for powering the device / platform and a socket 12 for powering electronic devices 18 (such as laptop computers). The power control system 10 can be implemented in any device / platform, illustratively including boats, motorcycles, residential or commercial buildings, etc.

[0074] Figure 3 A vehicle 20 coupled to a first power source 16 is depicted. Specifically, the vehicle 20 includes a charging inlet 22, and the first power source 16 includes a charger 24 configured to couple to the charging inlet 22 to provide power for charging the battery 14. The first power source 16 is illustrated as a commercial charging station; however, it should be understood that the first power source 16 could also be a residential outlet.

[0075] Vehicle 20 is an electric vehicle, and battery 14 is configured to supply power to motor 26 for driving vehicle 20. For example, motor 26 may be a motor configured to generate up to 200 horsepower to drive vehicle 20. Any battery 14 configured to be charged with electricity currently known or developed hereafter may be modified for use herein, illustratively including lithium-ion batteries, solid-state batteries, etc. The capacity of battery 14 is not required to be limiting and may include batteries 14 having a capacity greater than 30 kilowatt-hours (kWh). Battery 14 is also configured to supply power to various electrical components within vehicle 20. Such electrical components are well known and illustratively include lights, windshield wipers, main unit, heating, ventilation and air conditioning (HVAC) system, etc.

[0076] Figure 4 An exemplary configuration of an electric vehicle 20's power control system 10 is shown. The power control system 10 is coupled to a battery 14 and a first power source 16 via a charger 24. The power control system 10 includes a first inverter 28, a second inverter 30, and a winding machine 32. The first inverter 28 and the second inverter 30 are electrically isolated from each other. Each of the first inverter 28 and the second inverter 30 includes multiple transistors or metal-oxide-semiconductor field-effect transistors (“MOSFETs”) adapted to convert between direct current (DC) and alternating current (AC). The winding machine 32 includes windings separated into two electrically isolated winding groups 34. Each winding group 34 has its own neutral connection. The two winding groups 34 share the same stator core and have the same rotor. The windings may be electromagnetically symmetrical with respect to the winding machine 32 to avoid any imbalance, thereby increasing ease of control, etc., but in other configurations the windings may be electromagnetically asymmetrical with respect to the winding machine 32. The winding machine 32 may be a dual winding machine, wherein each winding machine is not directly connected but is inductively connected to the others. Exemplary winding machines include permanent magnet machines, winding magnetic field synchronizing machines, synchronous reluctance machines, or any AC machine in general.

[0077] The first inverter 28 can be used to convert between DC power at the first power source 16 and AC power at the motor 26. The second inverter 30 can be used to convert between DC power at the battery 14 and AC power at the motor 26. The power control system 10 can be coupled to the first power source 16 via a universal charger 24, which can be a socket to an external power grid that includes both DC and AC ports. The winding machine 32 can be integrated into the motor 26.

[0078] The power control system 10 includes a high-voltage DC bus 36 for connecting to a high-voltage socket of the charging inlet 22 and a low-voltage DC bus 38 for connecting to a low-voltage socket of the charging inlet 22.

[0079] The first DC port switch 40 controls the connection between the charging inlet 22 and the high-voltage DC bus 36.

[0080] The second DC port switch 42 controls the connection between the charging inlet 22 and the low-voltage DC bus 38. An AC bus 44 extends between the charging inlet 22 and the front-end rectifier 46. An AC port switch 48 on the AC bus 44 controls the connection between the charging inlet 22 and the front-end rectifier 46. An inductor may be deployed on the AC bus 44. The front-end rectifier 46 decouples the AC / DC power transfer between the charging inlet 22 and other components of the power control system 10, such as the first inverter 28. The front-end rectifier 46 may also be configured to make the voltage and current of the first power supply 16 in phase with the voltage and current of the battery 14.

[0081] The power control system 10 includes a battery busbar 50 having a positive current section 50A and a negative current section 50B. One end of the positive current section 50A is connected to the positive terminal (PT) of the battery 14 and the other end is connected to the vehicle load group 52, so that the positive current section 50A is inserted between the positive terminal (PT) and the second inverter 30. One end of the negative current section 50B is connected to the negative terminal (NT) of the battery 14 and the other end is connected to the vehicle load group 52, so that the negative current section 50B is inserted between the negative terminal (NT) and the second inverter 30. A positive contact switch 54 is deployed on the positive current section 50A and is inserted between the positive terminal (PT) of the battery 14 and the vehicle load group 52. A negative contact switch 64 is deployed on the negative current section 50B and is inserted between the negative terminal (NT) of the battery 14 and the vehicle load group 52. The positive contact switch 54 and the negative contact switch 64 are open when the vehicle 20 is not powered on and closed during charging and driving operations.

[0082] The vehicle load group 52 may include an auxiliary power module 58, a heater 60, an air compressor control unit 62, and other equipment 64 for operating the vehicle 10. The auxiliary power module 58 is configured to generate low-voltage power from the high-voltage bus to the vehicle 10. The heater 60 is configured to generate heat that can be used to heat the battery 14. The air compressor control unit 62 may include a sensor 66 for detecting the temperature of the battery 14.

[0083] The power control system 10 includes a third inverter 68 electrically coupled to a front-end rectifier 46 and a first inverter 28. The front-end rectifier 46 converts AC power to DC power. The third inverter 68 converts the DC power back to AC power for transmission to the socket 12. The DC power output from the third inverter 68 is transmitted to the first inverter 28, which converts the DC power into AC power for transmission to the winding machine 32. The winding machine 32 transmits the AC power to a second inverter 30, which converts the AC power back to DC power to charge the battery 14.

[0084] The power control system 10 includes a first switch 70 and a second switch 72. The first switch 70 is inserted between the positive bus 50A and the positive bus of the first inverter 28, and the second switch 72 is inserted between the negative bus 50B and the negative bus of the first inverter 28. The first switch 70 and the second switch 72 can be opened or closed to electrically disconnect and connect the second inverter 30 to the first inverter 28. With the first switch 70 and the second switch 72 open, the first inverter 28 and the second inverter 30 are electrically isolated from each other, so the operation of the first inverter 28 will not interfere with the operation of the second inverter 30 and the third inverter 68. Similarly, the charging of the battery 14 is not affected by the power supply to the socket 12.

[0085] The power control system 10 includes an on-board charger module 74, which includes a first processing unit 76 configured to process power from a first power source 16 to charge the battery 14 and simultaneously supply power to a socket 12. The first processing unit 76 includes non-volatile memory storing written instructions for executing the on-board charger module 74, including sending commands to operate the following: a first inverter 28, a second inverter 30, a winding machine 32, a front-end rectifier 46, a first DC port switch 40, a second DC port switch 42, an AC port switch 48, a vehicle load group 52, a positive contact switch 54, a negative contact switch 56, a third inverter 68, a first switch 70, and a second switch 72. For illustrative purposes, the on-board charger module 74 is shown as a unit transmitting signals to the power control system 10, as indicated by lightning. However, it should be understood that the on-board charger module 74 can be positioned to electrically communicate with the components of the power control system 10 using traces of buses, wires, or busbars. For example, the on-board charger module 74 can send gate signals to the MOSFETs of the first inverter 28, the second inverter 30, the front-end rectifier 46, and the third inverter 68 to perform DC-to-AC or AC-to-DC conversion as appropriate. Furthermore, the on-board charger module 74 can send gate signals to switches 40, 42, 48, 64, 66, 70, and 72, which open and close the switches to control the power supply between the components of the power control system 10.

[0086] The power control system 10 can also be configured to perform a series of steps to optimize battery charging operations. In one aspect, the on-board charger module 74 receives a signal from the charging inlet 22 indicating that power is being received. In this case, the on-board charger module 74 actuates the auxiliary power module 58 to generate the required low-voltage power. The on-board charger module 74 receives the temperature of the battery 14 from the sensor 66 or serial data and determines whether the temperature of the battery 14 is higher than a predetermined threshold. For illustrative purposes, it is assumed that the predetermined threshold is zero degrees Celsius. The on-board charger module 74 commands the first switch 70 and the second switch 72 to be in the open position, and the positive contact switch 54 and the negative contact switch 64 to be closed, to position the battery 14 and the socket 12 in electrical communication with the first power source 16. If the temperature of the battery 14 is higher than the predetermined threshold, the third inverter 68 is actuated, wherein power from the first power source 16 is transferred to the socket 12 when the battery 14 is being charged. If the temperature of the battery 14 is equal to or lower than the predetermined threshold, the on-board charger module actuates the heater 60 to heat the battery 14. Sensor 66 continues to monitor battery 14, and when the temperature of battery 14 exceeds a predetermined threshold, on-board charger module 74 commands positive contact switch 54 and negative contact switch 64 to close, and then actuates third inverter 68, and thus when battery 14 is charged, power from first power source 16 is transferred to socket 12.

[0087] Refer again Figure 4 In one aspect, rectifier 46 converts AC power to DC power and transmits the power to the first inverter 28. The first inverter 28 transmits the power to winding machine 32, which in turn transmits the power to the second inverter 30. In another aspect, the third inverter 68 includes a pair of capacitors and MOSFET switches coupled to an AC filter 78, which filters the power before it is received by socket 12. In yet another aspect, the third inverters 68, 68a can also be configured to boost or buck the voltage from the first power supply 16. For example, if the first power supply 16 provides 120 volts of AC power and socket 12 is configured to provide 120 volts of AC power, it should be understood that the third inverters 68, 68a do not need to perform boost or buck operations. However, if the first power source 16 is configured to provide 120 volts of AC power and the socket 12 is configured to provide 240 volts of AC power, then the third inverters 68, 68a can be configured to boost the power from the first power source 16 to provide 240 volts of AC power to the socket 12.

[0088] Now for reference Figure 5The power control system 10 can also be configured to handle a first power supply 16, which is configured to output power in a three-phase configuration. In this respect, the third inverter 68b is configured as a three-phase inverter. In one aspect, the three-phase inverter may include three pairs of MOSFET switches connected in parallel, and each pair of MOSFET switches is configured not only to convert DC power from the front-end rectifier 46 to AC power, but also to transmit power in three different phases to the socket 12. Figure 5 An aspect is also described in which not only is power delivered to socket 12 in three phases, but power from the first power source 16 can be boosted or bucked to meet the requirements of socket 12. Specifically, power from the third inverter 68b is passed through an AC filter 78. As described above, the AC filter 78 is configured to filter noise from the power, and the third inverter 68b can also be configured to boost or buck the power. Therefore, when the first power source 16 provides three-phase 120V AC power and socket 12 is configured to provide three-phase 120V power, it should be understood that the third inverter 68b does not need to perform boost or buck operation. However, if the first power source 16 is configured to provide 120V AC power and socket 12 is configured to provide 240V AC power, then the third inverter 68b can be configured to boost the power from the first power source 16 to provide 240V AC power to socket 12.

[0089] Now for reference Figure 6This provides an alternative configuration for the third inverter 68c of the power control system 10. The third inverter 68c can be a single-phase inverter, where the power transmitted by the front-end rectifier 46 is converted into a single-phase form. In this aspect, the front-end rectifier 46 receives power from the first power source 16 in three different phases, as indicated by the three lines coupling the charging port 22 to the front-end rectifier 46. In this aspect, the power control system 10 may also include a relay matrix 80 configured to supply power directly from the charging port 22 to the socket 12, or to supply boosted or bucked power from the third inverter 68c. In this aspect, where 120 volts of power is received from the charging port 22 and the socket 12 is configured to supply 120 volts, the front-end rectifier 46 can be turned off, thus forming an open circuit. In this case, power from the charging port 22 is directly transmitted along power lines P1 and P2 to the relay matrix 80, which then feeds power to the socket 12. When receiving 120 volts of power from charging port 22 and socket 12 is configured to provide 240 volts, front-end rectifier 46 can be turned on to form a closed circuit. In this case, power from charging port 22 is directly transmitted along power lines P1 and P2 to relay matrix 80 and front-end rectifier 46. Front-end rectifier 46 converts the power to DC power, and third inverter 68c converts the DC power to AC power and boosts the power to 240 volts. Relay matrix 80 processes the power from third inverter 68c and power lines P1 and P2 to generate the 240 volts to be fed to socket 12. It should be understood that front-end rectifier 46 can be turned on to form a closed circuit when receiving 240 volts of power from charging port 22 and socket 12 is configured to provide 120 volts. In this configuration, power from charging port 22 is directly transmitted along power lines P1 and P2 to relay matrix 80, and power is also transmitted from front-end rectifier 46 to third inverter 68c. Third inverter 68c steps down the power and transmits the stepped-down power to relay matrix 80, which mixes the power from power lines P1 and P2 with that from third inverter 68c to generate 120 volts of power to be fed to power socket 12.

[0090] Now for reference Figure 7A method is provided for simultaneously supplying power from a first power source 16 to a socket 12 and charging a battery 14 of an electric vehicle 20. The battery 14 is configured to power a motor 26 driving the electric vehicle 20. This method can be implemented by an on-board charger module 74 configured to process power from the first power source 16 to charge the battery 14 and supply power to the socket 12. The on-board charger module 74 includes a first inverter 28, a second inverter 30, a winding machine 32, and a front-end rectifier 46. The front-end rectifier 46 converts power from alternating current (AC) to direct current (DC). The first inverter 28 converts DC to AC and transmits the AC to the winding machine 32. The winding machine 32 transmits the AC to the second inverter 30. The second inverter 30 converts the AC to DC and transmits the DC to the battery 14 to charge it. The third inverter 68 is electrically coupled to the front-end rectifier 46, and the third inverter 68 is configured to convert DC power from the front-end rectifier 46 into AC power, and to transmit AC power to the socket 12 when the battery 14 is being charged.

[0091] At step 200, power factor correction is performed. At step 202, components of the vehicle load group 52 required for battery charging operation are switched on. For example, the heater 60, auxiliary power module 58, and air compressor control unit 62 are switched on. At step 204, the voltage and current of the first power supply 16 are made in phase with the voltage and current of the battery 14. This can be performed by the front-end rectifier 46.

[0092] At step 206, the third inverter 68 is actuated, and at step 208, it is determined whether the temperature of battery 14 is greater than a predetermined threshold, for example, whether the temperature of battery 14 is above zero degrees Celsius. Step 208 is executed until the temperature of battery 14 is greater than the predetermined threshold. As heater 60 is turned on, the temperature of battery 14 rises. At step 210, when the battery temperature is greater than the predetermined threshold, positive contact switch 54 and negative contact switch 64 are closed. At step 212, the method continues to query whether charging is complete. When the charging operation is complete, the method ends at step 214. It should be understood that the charging operation can be completed when battery 14 is fully charged or charger 24 is disconnected from charging port 22. In such cases, vehicle 20 is disconnected from first power source 16, and power is supplied from battery 14 to socket 12.

[0093] It should be understood that this method can be implemented regardless of the electrical characteristics of the first power source 16. Similarly, the third inverter 68 can be configured to receive power in either single-phase or three-phase mode. Additionally, the third inverter 68 can be configured to increase and / or decrease the voltage of the power supply to deliver power to the socket at a predetermined voltage. As described above, such features are useful in instances where the first power source 16 provides 120 volts and the socket 12 is configured to provide 240 volts.

[0094] The method may further include the step of providing a first switch 70 and a second switch 72. The first switch 70 is inserted between the battery 14 and the second inverter 30, and the second switch 72 is inserted between the battery 14 and the first inverter 28. The method includes the step of keeping the first switch 70 and the second switch 72 open while the battery 14 is being charged, to provide electrical isolation between the power supplied to the socket 12 and the battery 14 during charging. As discussed above, when charging is complete and the charger 24 is disconnected from the charging inlet, the battery 14 supplies power to the socket 12, which can be accomplished by closing the first switch 70 and the second switch 72.

[0095] In some embodiments, the method further includes detecting the temperature of the battery and closing the positive contact switch 54 and the negative contact switch 64 when the temperature of the battery 14 is above a predetermined threshold, and turning on the heater 60 to heat the battery when the temperature of the battery 14 is below the predetermined threshold. The method may include the step of keeping the positive contact switch 54 and the negative contact switch 64 in the open position until the temperature of the battery 14 is equal to or above the predetermined threshold. The method may include the step of closing the first switch 70 and the second switch 72 when the battery 14 supplies power to the motor 26.

[0096] Several 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 within the scope of the following claims.

[0097] The foregoing description is provided for illustrative purposes only and is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable, and may be used in the chosen configuration even if not specifically shown or described. Elements or features of a particular configuration may also vary in many ways. Such variations should not be considered a departure from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A power control system for supplying power to a socket and a battery, the battery being configured to power a motor, the power control system supplying the power from a first power source to the socket and the battery, the power control system comprising: An on-board charger module includes a first processing unit configured to process power from a first power source to charge the battery. The first processing unit includes a non-volatile memory storing written instructions for executing the on-board charger module. The on-board charger module includes a first inverter, a second inverter, a winding machine, and a rectifier, wherein the first inverter, the winding machine, and the second inverter are configured to transmit power from the first power source to the battery, and the rectifier is configured to convert alternating current (AC) from the first power source into direct current (DC). A third inverter is electrically coupled to the rectifier and the first inverter; A first switch is inserted between the battery and the first inverter; A second switch is inserted between the battery and the second inverter; as well as The first processing unit is further configured to keep the first switch and the second switch in the off position when the battery is being charged, so as to provide electrical isolation between the battery and the third inverter when the battery is being charged, while the third inverter converts the DC power from the rectifier into AC power and supplies the AC power to the socket to allow power to the load when the battery is being charged.

2. The power control system according to claim 1, wherein the first switch is inserted between the battery and the second inverter, and the second switch is inserted between the battery and the first inverter.

3. The power control system according to claim 1 further includes a positive contact switch and a negative contact switch, the positive contact switch being inserted between the positive terminal of the battery and the second inverter, and the negative contact switch being inserted between the negative terminal of the battery and the second inverter.

4. The power control system of claim 1, wherein the third inverter is configured to supply voltage to the socket in a single phase.

5. The power control system of claim 1, wherein the third inverter is configured to supply voltage to the socket in at least two phases.

6. The power control system of claim 3, wherein the rectifier is further configured to make the voltage and current of the first power supply in phase with the voltage and current of the battery.

7. The power control system of claim 6, further comprising a heater and a sensor for detecting the temperature of the battery.

8. The power control system of claim 7, wherein the on-board charger module is further configured to disconnect the first switch and the second switch, and close the positive contact switch and the negative contact switch when the voltage and current of the first power supply are in phase with the voltage and current of the battery and the temperature of the battery is higher than a predetermined threshold.

9. The power control system of claim 8, wherein the on-board charger module is further configured to disconnect the positive contact switch and the negative contact switch when the temperature of the battery is equal to or lower than the predetermined threshold.

10. The power control system of claim 9, wherein the on-board charger module is further configured to close the first switch and the second switch when the battery supplies power to the motor.

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