Charger for charging an electric or hybrid vehicle

Abstract

Charger (1) for charging an electric or hybrid vehicle, wherein the charger (1) has connections (AC-L1, AC-L2, AC-L3, AC-N) for an external AC power supply, a rectifier (2), a galvanically isolated DC / DC converter (3) and a control unit (13), wherein switching elements (S) are arranged at the connections (AC-L1, AC-L2, AC-L3, AC-N) for the external AC power supply, wherein the control unit (13) is configured to control at least the switching elements (S) and the rectifier (2), wherein the charger (1) has a transformer (6) with a primary winding (8) and a secondary winding (9), wherein the primary winding (8) is connected to an AC input of the DC / DC converter (3) and the secondary winding (9) is connected to the control unit (13) via a second rectifier (12), wherein lines (10) extend from the connections (AC-L1, AC-L2, AC-L3,AC-N) to the rectifier (2) as windings (11) around the transformer (6), wherein the charger (1) is designed to operate on the basis of a changing voltage (U, sec ) to conclude that there is a fault current at the secondary winding (9) and to open the switching elements (S).

Description

[0001] The invention relates to a charger for charging an electric or hybrid vehicle in a motor vehicle.

[0002] These on-board chargers enable the charging of a high-voltage battery in a vehicle from an external AC power supply. The charger has connections for this purpose, allowing it to be connected to the external charging station. The AC voltage is then rectified into a DC voltage within the charger and adapted to the charging voltage of the high-voltage battery using a DC / DC converter. For safety reasons, these DC / DC converters are preferably designed as galvanically isolated DC / DC converters.

[0003] Due to a variety of causes, fault currents can occur during charging. These fault currents can lead to potentials that pose a hazard. Therefore, residual current monitoring devices are used that interrupt the charging process when a fault is detected. A distinction is made between Type A and Type B residual current circuit breakers (RCCBs). Type A RCCBs detect only purely sinusoidal alternating currents and pulsating direct current fault currents. Type B RCCBs are also known as all-current-sensitive RCCBs, which can also detect smooth direct current fault currents.

[0004] From DE 10 2009 034 887 A1 and DE 10 2010 028 626 A1, charging stations for electric vehicles are known that have residual current circuit breakers.

[0005] From EP 0 248 320 A1, an arrangement for detecting fault currents is known with a summation current transformer, the primary circuit of which is formed by network conductors and the secondary circuit of which contains a holding magnet and whose magnetic core is provided with a pre-magnetization winding through which an excitation current flows. A voltage monitoring system is provided in the secondary circuit, which triggers the holding magnet when a predetermined limit value of a component of the voltage in the secondary circuit is undershot at the same frequency as the excitation current in the pre-magnetization winding.

[0006] From DE 10 2021 124 917 A1, a transformerless charging station for charging an electric vehicle's energy storage system with electrical energy is known, comprising an AC / DC converter for converting an alternating voltage supplied by the multiphase network via the phases into a direct voltage supplied via a DC+ and a DC line, and a control device for controlling components of the charging station. Furthermore, the charging station has a residual current sensor associated with the phases and the neutral conductor, which is configured to detect a time-varying residual current with a DC component and an AC component. A switching device is provided for opening and closing the phases and the neutral conductor of the charging station.

[0007] The invention is based on the technical problem of creating an on-board charger for an electric or hybrid vehicle that has integrated residual current monitoring.

[0008] The solution to the technical problem is provided by a charger having the features of claim 1. Further advantageous embodiments of the invention are set forth in the dependent claims.

[0009] For this purpose, the charger for charging an electric or hybrid vehicle has connections for an external AC power supply, a rectifier, a galvanically isolated DC / DC converter, and a control unit. Switching elements are arranged at the connections for the external AC power supply. The control unit is designed to control at least the switching elements and the rectifier. Preferably, the control unit also controls the DC / DC converter. Furthermore, the charger has a transformer with a primary winding and a secondary winding, wherein the primary winding is connected to an AC voltage input of the DC / DC converter and the secondary winding is connected to the control unit via a second rectifier.

[0010] Furthermore, wires from the terminals to the rectifier are wound around the transformer or transformer core. The charger is designed to detect a fault current based on a changing voltage across the secondary winding and to open the switching elements. The basic principle is that the windings of the wires from the terminals form a summation current transformer. In the fault-free state, the sum of the currents is zero. In the event of a fault, the sum of the currents is not zero and generates a magnetic flux that reduces the coupling between the primary and secondary windings, thus decreasing the secondary voltage.

[0011] In one embodiment, the second rectifier is connected to a supply voltage terminal of the control unit. The transformer thus serves not only to detect a fault current, but also provides the supply voltage for the control unit during charging operation.

[0012] In another embodiment, the second rectifier is connected to a comparator, which is configured to generate a fault current signal when the voltage across the rectifier is lower than a reference voltage. The advantage of a comparator is that fault current detection is very fast and robust. Redundant fault current detection is also possible, performed both via the comparator and via the control unit.

[0013] In one embodiment, the comparator, and in particular its output, is connected to the control unit. Depending on a detected fault current signal, the control unit can then generate switching commands for the switching elements, opening them and switching off the rectifier.

[0014] In an alternative embodiment, the output of the comparator is connected to at least one gate through which the switching signals for the switching elements and the rectifier are routed, so that a hardware device generates the shutdown commands.

[0015] In another embodiment, the reference voltage is selected to be higher than a minimum operating voltage of the control unit. This ensures that the control unit remains operational even if shutdown is triggered by a fault current and the voltage at the second rectifier is the operating voltage of the control unit.

[0016] In another embodiment, the reference voltage is set via a Zener diode.

[0017] In another embodiment, the charger has connections for a three-phase AC power supply.

[0018] The invention is explained in more detail below with reference to a preferred embodiment. The figures show: Fig. 1 a schematic block diagram of an on-board charger, Fig. 2 a schematic representation of a coupling factor versus magnetic flux and Fig. 3 Time profiles of different signals in the event of a fault current event.

[0019] In the Fig. Figure 1 schematically depicts a charger 1. The charger 1 has terminals AC-L1, AC-L2, AC-L3, and AC-N for a three-phase external AC power supply (not shown). The terminals AC-L1, AC-L2, AC-L3, and AC-N are connected to a rectifier 2 via switching elements S. The switching elements S are preferably designed as relays, with only one switching element S being designated with a reference numeral. The rectifier 2 has an input inductance L for each AC phase, the other end of which is connected to a center tap of a half-bridge. The neutral conductor AC-N is also connected to a half-bridge. Switches S1-S8, preferably designed as IGBTs or MOSFETs, are arranged in the four half-bridges.Rectifier 2 is connected to a galvanically isolated DC / DC converter 3, with a DC link capacitor C arranged between rectifier 2 and the galvanically isolated DC / DC converter 3. The DC / DC converter 3 has an input half-bridge consisting of two switches S9 and S1. 10 to which two series-connected capacitors C9, C10 are connected in parallel. Furthermore, a first winding 4 is provided, which is connected on one side to a center tap between the two switches S9, S10. 10and, on the other hand, is connected to a center tap between the two capacitors C9 and C10. The two center taps represent the AC voltage input of the DC / DC converter 3. On the output side, the DC / DC converter 3 is configured as a mirror image of the input. Visually, the input-side half-bridge chops the DC voltage into an AC voltage, which is then inductively transferred from the first winding 4 to a second winding 5, with the AC voltage being switched on the output side via the half-bridge by the switches S 11 , S 12 and the capacitors C11, C12 are rectified again and are available for charging a high-voltage battery (not shown).

[0020] Furthermore, the charger 1 has a transformer 6 with a core 7. A primary winding 8 and a secondary winding 9 are wound on the core 7. The primary winding 8 is connected to the AC voltage input (the two center taps) of the DC / DC converter 3. The leads 10 from the terminals AC-L1, AC-L2, AC-L3, and AC-N are wound as windings 11 around the core 7 before being connected to the rectifier 2. The secondary winding is connected to a second rectifier 12, which consists, for example, of two diodes D and two capacitors C13. A DC voltage U is then present at the output of the second rectifier 12. CC to.

[0021] Furthermore, the charger 1 has a control unit 13 which provides the control signals for the switching elements S, the switches S1-S8 of the rectifier 2 and the switches S9-S 12A DC / DC converter 3 generates a comparator. A comparator 14 is arranged between the output of the second rectifier 12 and the control unit 13, its positive input being connected to the output of the second rectifier 12. The negative input is connected to a reference voltage U. ref , which is set using a Zener diode Z. The voltage U CC The output of the second rectifier 12 also provides the supply voltage for the control unit 13.

[0022] To start the charging process, the control unit 13 must be briefly supplied with voltage. This can be done, for example, from an on-board electrical system (not shown) or a battery. Alternatively, the DC / DC converter can briefly supply voltage from the high-voltage battery. The control unit 13 then generates a control signal f to close the switching elements S. The AC voltages are then rectified by the rectifier 2 and adapted to the charging voltage of the high-voltage battery by the DC / DC converter 3.

[0023] The operating principle of charger 1 will now be explained using the following: Fig. 2 and Fig. 3 will be explained in more detail, whereby in Fig. 2 a coupling k between the primary winding 8 and the secondary winding 9 is shown due to a magnetic flux ϕ in the core 7.

[0024] In the Fig. 3 above is the total current i = i L1 + i L2 + i L3 + i L4As shown. In fault-free operation, the total current i = 0 and generates no magnetic flux ϕ. Accordingly, a large, constant magnetic coupling k exists between the primary winding 8 and the secondary winding 9, resulting in a large secondary voltage U. sec adjusts the voltage U accordingly. CC greater than the reference voltage U ref And a 1 is present at the output of comparator 14 (e=1). If an error occurs at time t0, resulting in a non-zero total current, a magnetic flux ϕ develops, causing the magnetic coupling k to decrease. Consequently, the secondary voltage U drops. sec and the voltage U CC drops below the reference voltage U ref As a result, the output signal e=0 at comparator 14 is open. The switching elements S and the switches S1-S6 are opened. This can be implemented, for example, by AND gates 15 (see also Fig.1), whereby a zero is always present at the output of gate 15 when the signal e=0. The control unit 13 can then subsequently discharge the intermediate circuit capacitor C by driving the DC / DC converter 3. Reference symbol list 1 charger 2 rectifiers 3 DC / DC converters 4 first winding 5 second winding 6 Transformer 7 core 8 Primary winding 9 Secondary winding 10 Management 11 winding 12 rectifiers 13 Control unit 14 Comparator 15 gates AC-L1 connection AC-L2 connection AC-L3 connection AC_N connection C Intermediate circuit capacitor C9-C13 capacitors D diode e fault current signal k coupling S switching element S1-S 12 Switch U CCTension U ref Reference voltage U sec Secondary voltage Z Zener diode

Claims

Charger (1) for charging an electric or hybrid vehicle, wherein the charger (1) has connections (AC-L1, AC-L2, AC-L3, AC-N) for an external AC power supply, a rectifier (2), a galvanically isolated DC / DC converter (3) and a control unit (13), wherein switching elements (S) are arranged at the connections (AC-L1, AC-L2, AC-L3, AC-N) for the external AC power supply, wherein the control unit (13) is configured to control at least the switching elements (S) and the rectifier (2), wherein the charger (1) has a transformer (6) with a primary winding (8) and a secondary winding (9), wherein the primary winding (8) is connected to an AC input of the DC / DC converter (3) and the secondary winding (9) is connected to the control unit (13) via a second rectifier (12), wherein lines (10) extend from the connections (AC-L1, AC-L2, AC-L3,AC-N) to the rectifier (2) as windings (11) around the transformer (6), wherein the charger (1) is designed to detect a fault current based on a changing voltage (Usec) at the secondary winding (9) and to open the switching elements (S). Charger according to claim 1, characterized in that the second rectifier (12) is connected to a supply voltage connection of the control unit (13). Charger according to claim 1 or 2, characterized in that the second rectifier (12) is connected to a comparator (14), wherein the comparator (14) is configured to generate a fault current signal (e) when the voltage (UCC) at the rectifier (12) is less than a reference voltage (Uref). Charger according to claim 3, characterized in that the output of the comparator (14) is connected to the control unit (13). Charger according to claim 3, characterized in that the output of the comparator (14) is connected to at least one gate (15). Charger according to one of claims 3 to 5, characterized in that the reference voltage (Uref) is selected to be greater than a minimum operating voltage of the control unit (13). Charger according to one of claims 3 to 6, characterized in that the reference voltage (Uref) is set via a Zener diode (Z). Charger according to one of the preceding claims, characterized in that the charger (1) has connections (AC-L1, AC-L2, AC-L3, AC-N) for a three-phase AC power supply.

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