POWER CONTROL SYSTEM WITH A POWER SPLITTER MODULE

Abstract

A power control system is provided to supply power to a load and a battery from a primary power source. The primary power source delivers electrical power at a predetermined voltage to an onboard charging control module, which regulates the power to charge the battery. The onboard charging module is configured to process the electrical power from the primary power source to charge the battery. A splitter module is inserted between the primary power source and the onboard charging control module. The splitter module is configured to direct electrical power from the primary power source to the load. Therefore, power can be supplied to the load while the battery is being charged.

Description

INTRODUCTION

[0001] The present invention relates generally to a power distribution system according to the preamble of claim 1 for charging a battery, as is known essentially from US 2024 / 0 072 544 A1. Further prior art is described in WO 2024 / 186 042 A1.

[0002] An electric vehicle contains, for example, a battery to power a motor, which in turn powers the vehicle and its electrical components, such as a main unit, lights, air conditioning, and so on. Some electric vehicles include one or more outlets that users can use to power personal electrical devices, such as cell phones and tablets.

[0003] The electric vehicle also includes an inlet for receiving power from a charger connected to a utility grid to charge the battery. The inlet can be configured to accept alternating current (AC) at either 120 volts or 240 volts. The charging power is regulated and controlled by an onboard charging control module (OBCM). Currently, the OBCM shuts off power to the outlets in the electric vehicle while the battery is charging to facilitate regulation and control of the power to the battery when the charger is connected to the inlet.

[0004] Many electrical devices that can be connected to a vehicle outlet are configured to receive 120 volts of alternating current power.

[0005] Consequently, directly connecting such electrical devices to a charger receiving power from a 240-volt source can damage the electrical device. Furthermore, such electrical devices may be configured to operate using power with different signal waveforms.

[0006] Accordingly, it is desirable to have a power distribution system where the outlets can be actuated to distribute power when the battery is charging. Furthermore, it is desirable to have a power distribution system configured to step up or step down power from a power source to provide power to a specified electrical device. It is also desirable to be able to adjust the power signal waveform to adapt it to a specified electrical device. SUMMARY

[0007] According to the invention, a power control system is presented which is characterized by the features of claim 1.

[0008] The first power source is configured to deliver electrical power in the form of alternating current. The power control system includes an onboard charging control module and a splitter module. The onboard charging module contains a first processing unit configured to process the electrical power from the first power source to charge the battery. The splitter module is inserted between the first power source and the onboard charging control module. The splitter module is configured to direct electrical power from the first power source to the load. For example, the splitter module can be configured to supply power to an outlet to which the load can be connected. Accordingly, power can be supplied to the load while the battery is being charged.

[0009] According to some examples, the on-board charging control module can be configured to provide galvanic isolation between the load and the battery.

[0010] Depending on some configurations, the splitter module can be configured to change the voltage of the electrical power. For example, the splitter module can be configured to step the voltage up or step it down.

[0011] Depending on some configurations, the second processing unit can also be configured to actuate the AC / AC converter to generate a predefined signal waveform. For example, the first processing unit of the on-board charging control module can be configured to transmit the battery charging information to the second processing unit of the AC / AC converter, which then processes the charging information to control the switch and maintain a target signal waveform.

[0012] According to some configurations, the AC / AC converter includes, for example, either a step-down converter, a step-up / step-down converter, or a single-ended primary inductor converter.

[0013] According to some configurations, the on-board charging control module and the splitter module are integrated as a single module.

[0014] Furthermore, an electric vehicle is described that includes a battery, an inlet, and an outlet. The battery is configured to supply power to the electric vehicle's drive system. The inlet is configured to receive electrical power from a first power source, while the outlet is configured to supply power to a load. The electric vehicle also includes an on-board charging control module that is electrically coupled to the inlet. The on-board charging control module includes a first processing unit configured to process the electrical power from the first power source to charge the battery. The electric vehicle also includes a splitter module that is electrically coupled to the outlet.The splitter module is inserted between the inlet and the on-board charging control module to direct electrical power from the first power source to the outlet to supply power to the load while simultaneously charging the vehicle.

[0015] This aspect of the invention may include one or more of the following optional features. According to some examples, the splitter module may be configured to change the voltage of the electrical power. For example, the splitter module may be configured to step down the voltage of the first power source. According to such an example, the splitter module may include a sensing unit configured to measure a current and / or voltage value, and / or a switch that can be actuated to bypass or turn on an AC / AC converter.

[0016] According to some implementations, the splitter module can include a second processing unit, where the second processing unit receives the measured current and / or voltage value to actuate the switch. The second processing unit can further be configured to actuate the AC / AC converter to generate a predefined waveform.

[0017] According to some implementations, the first processing unit of the on-board charging control module can transmit the battery charging information to the second processing unit of the AC / AC converter, with the second processing unit processing the charging information to control the switch and maintain the desired signal shape.

[0018] According to some implementations, the outlet is either a two-pole or a three-pole outlet. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The drawings described here serve only to illustrate selected configurations; they show: Fig. 1 a perspective view of a vehicle showing a power control system of the vehicle coupled to a first power source; Fig. 2 a schematic view of the in Fig. 1 performance control system shown; Fig. 3 A schematic view of an AC / AC converter of a Fig. 2 splitter modules shown; Fig. 4 a schematic view of a splitter module configured to bridge the AC / AC converter; Fig. 5 a graphical representation showing a waveform output by the first power source; and Fig. 6 a graphical representation showing the in Fig. The signal waveform shown in Figure 5 is modified by the splitter module.

[0020] The corresponding reference symbols in all drawings indicate the corresponding parts. DETAILED DESCRIPTION

[0021] The present invention relates to a power control system 10 for supplying power to a load and a battery 14 from a first power source 16. The first power source 16 transmits electrical power in the form of alternating current at a predetermined voltage to an on-board charging control module 18, which regulates the power to charge a battery 14. The first power source 16 can be a commercially developed charging station configured to supply electrical power at 240 volts or a household outlet configured to supply power at 120 volts.

[0022] The on-board charging control module 18 contains a first processing unit 20 configured to process the electrical power from the first power source 16 to charge the battery 14. A splitter module 22 is inserted between the first power source 16 and the on-board charging control module 18. The splitter module 22 is configured to direct electrical power from the first power source 16 to the load. The splitter module 22 can, for example, be configured to supply power to an outlet 24 located in the vehicle 26, to which the load can be connected. The outlet 24 can be a standard two- or three-pole outlet for use in the United States or a two-pole outlet for use in Europe. Accordingly, power can be supplied to the load 12 while the battery 14 is being charged.

[0023] The power control system 10 can be implemented in any platform or device that uses a battery 14 to supply power to the device, such as a motor to drive the device. For illustrative purposes, the power control system 10 is described in the context of an electric vehicle 26, as shown in Fig. Figure 1 shows. However, it should be recognized that the power control system 10 may be implemented in other devices / platforms which have a battery 14 for supplying power to the device / platform and an outlet 24 for supplying power to a load, such a device / platform being, for illustrative purposes, a boat, a motorcycle, a residential or commercial building, and the like.

[0024] Fig. Figure 1 shows the vehicle 26 coupled to the first power source 16. Specifically, the vehicle 26 includes a charging inlet 28, while the first power source 16 includes a charger 38 configured to be coupled to the charging inlet 28 to provide power for charging the battery 14. The first power source 16 is shown for illustrative purposes as a commercial charging station, but it should be recognized that the first power source 16 could just as easily be a household electrical outlet.

[0025] The vehicle 26 is an electric vehicle 26 with a battery 14 configured to supply power to a motor 30 for propelling the vehicle 26. The motor 30 can, for example, be an electric motor 30 configured to generate up to 200 horsepower to propel the vehicle 26. Any battery 14 configured to be charged with electrical power currently known or subsequently developed, including, for illustrative purposes, lithium-ion batteries, solid-state batteries, and the like, can be modified for use here. The capacity of the battery 14 need not be limited and can include batteries 14 with a capacity greater than 30 kilowatts (kW). The battery 14 is further configured to supply power to the various electronic components within the vehicle 26.Such electronic components are well known and include, for example, lights, windshield wipers, a main unit, heating and air conditioning systems, and the like.

[0026] In the Fig. 2 and Fig. Figure 3 of the power control system 10 includes an on-board charging control module 18 and a splitter module 22. In some configurations, the on-board charging control module 18 and the splitter module 22 are integrated as a single module. In other configurations, the on-board charging control module 18 and the splitter module 22 are separate units. The on-board charging control module 18 is configured to regulate the power from the first power source 16 to charge the battery 14. The on-board charging control module 18 may, for example, contain electronic circuits and components configured to filter out noise, maintain the power supplied to the battery 14 at a predetermined voltage, maintain a predetermined waveform, and perform other routine processes to supply the battery 14 with power that is optimal for the charging operations. The on-board charging control module 18 may, for example,a power factor correction circuit is included which is configured to regulate the power for the battery 14 and one or more power outlets 24 within the vehicle 26.

[0027] The on-board charging control module 18 contains switches 32, such as MOSFET switches, which can be turned on and off to control a duty cycle of the electrical power, to step up or step down the voltage, and to change the waveform of the electrical power supplied to the battery 14. The on-board charging control module 18 can also be configured to provide galvanic isolation between the load and the battery 14. For example, the on-board charging control module 18 can also include an isolated DC / DC converter, which may contain a transformer. The operation of the transformer provides galvanic isolation between the load and the battery 14.

[0028] The on-board charging control module 18 can include a first processing unit 20, which is configured to actuate the electronic components, such as the switches 32, to process the electrical power from the first power source 16 to charge the battery 14. The first processing unit 20 contains written instructions for the execution of the electronic components. The instructions can be stored in non-volatile memory, which can be updated as needed.

[0029] Back in Fig. 2 and now in Fig. Figure 3 of the power control system 10 includes a splitter module 22, which is inserted between the first power source 16 and the on-board charging control module 18. According to one aspect, the first power source 16 includes a first output line 34 and a second output line 36, with power being supplied by the first output line 34 and the second output line 36. According to this aspect, the second output line 36 is a neutral line to create a power differential with respect to the first output line 34 for the supply of power. The first output line 34 and the second output line 36 can be housed within a charger 38 of the first power source 16 and are configured to be connected to the charging inlet 28 located on the vehicle 26. The on-board charging control module 18 includes a first input line 40 and a second input line 42, which are configured to be electrically connected to the first output line 34 and the second input line 42, respectively.The second output line 36 is connected to receive power from the first power source 16. The first input line 40 and the second input line 42 are electrically connected to the electronic components of the on-board charging control module 18, which regulates the supplied power.

[0030] The splitter module 22 includes a third input line 44 and a fourth input line 46, configured to direct electrical power from the first power source 16 to the load. The third input line 44 and the fourth input line 46 are electrically coupled to the first output line 34 and the second output line 36, respectively. It should be noted that the first input line 40, the second input line 42, the third input line 44, and the fourth input line 46 can be located in the charging inlet 28. It should also be noted that the splitter module 22 does not necessarily provide a direct electrical connection to the load, but can be configured to supply power to the outlet 24, to which the load can be connected. Accordingly, power can be supplied to the load while the battery 14 is being charged.It should be recognized that the first output line 34, the second output line 36, the first input line 40, the second input line 42, the third input line 44 and the fourth input line 46 may be formed from an electrically conductive wire or a cable formed from several electrically conductive wires.

[0031] Back in Fig. 2 and now in Fig. 3 The splitter module 22 contains an AC / AC converter 48 configured to regulate the power from the first power source 16. Any currently known or subsequently developed AC / AC converter 48 can be modified for use here, including, by way of illustration, a step-down converter, a step-up / step-down converter, a single-ended primary inductor converter 58, a switching capacitor AC / AC converter, and a push-pull AC / AC converter.

[0032] According to one aspect, the AC / AC converter 48 includes a first capacitor 50 and a second capacitor 52, which connect the third input line 44 to the fourth input line 46. A first switch 54 is inserted between the first capacitor 50 and the second capacitor 52, so that it is connected in parallel to the third input line 44 and the fourth input line 46, and connects or disconnects the power between the third input line 44 and the fourth input line 46. A second switch 56 is arranged in the fourth input line 46, which is electrically connected to the second output line 36. The second switch 56 is also inserted between the first switch 54 and the second capacitor 52. The AC / AC converter 48 may further include an inductor 58, which is arranged in the fourth input line 46 and connected in series with the second switch 56.The inductor 58 is inserted between the first switch 54 and the first capacitor 50. By actuating the first switch 54 and the second switch 56, the splitter module 22 can be configured to change the voltage and the waveform of the electrical power. The splitter module 22 can, for example, be configured to step up or step down the voltage supplied to the load.

[0033] In Fig. The splitter module 22 is configured to bypass the AC / AC converter 48. The splitter module 22 can, for example, contain a sensing unit 60 configured to measure a current and / or voltage value. The sensing unit 60 can be any currently known or subsequently adapted current or voltage sensor that can be modified for use here to include a resistor, a diode, a combination of a resistor and a diode, or the like. The sensing unit 60 is operationally coupled to a first switch 54 and a second switch 56, respectively, to detect or otherwise measure the current and / or voltage at the first switch 54 and the second switch 56.The acquisition unit 60 is coupled via communication technology to a second processing unit 62, which is configured to measure the value of the voltage and / or current in order to control the operation of the first switch 54 and the second switch 56.

[0034] The splitter module 22 can include a third switch 64, which can be actuated to bypass or switch on the AC / AC converter 48. In this configuration, the splitter module 22 includes a fifth input line 66, which is connected in parallel to the fourth input line 46, bypassing the inductor 58, the first switch 54, and the second switch 56.

[0035] The second processing unit 62 receives the measured value of the current and / or voltage in order to actuate the third switch 64. Consequently, in cases where the first power source 16 provides power at 240 volts, the first sensing unit 60 detects the voltage and / or current, while the second processing unit 62 keeps the third switch 64 off to supply power to the AC / AC converter 48. In such a case, the second processing unit 62 further actuates the first switch 54 and the second switch 56 to step down the power to 120 volts to generate a predetermined duty cycle in order to output a signal waveform suitable for commercial electronic devices, such as laptop computers and / or mobile devices.In cases where the first power source 16 provides power at 120 volts, the detection units 60 detect that power is being provided at 120 volts, with the second processing unit 62 keeping the third switch 64 open to bypass the AC / AC converter 48. The 120 volts from the first power source 16 are output directly to the inlet.

[0036] In the Fig. 5 and Fig. Figure 6 provides a representation of the signal shape output by the splitter module 22. Fig. Figure 4 shows an example of a signal waveform output by the first power source 16. The signal waveform is generally sinusoidal, which may not be optimal for some electronic devices. The second processing unit 62 can further be configured to actuate the AC / AC converter 48 to generate a predetermined signal waveform. For example, the first processing unit 20 of the on-board charging control module 18 can be configured to transmit the charging information of the battery 14 to the second processing unit 62 of the AC / AC converter 48, the second processing unit 62 processing the charging information to control the switch and maintain a desired signal waveform, as shown in Figure 4. Fig. 5 is shown. This can be done by selectively actuating the first switch 54 and the second switch 56.

[0037] Once again in the Fig. 3 and Fig. 4 provides an operating mode for the power control system 10. In operation, the charger 38 of the first power source 16 is coupled to the charging inlet 28. The splitter module 22 draws power from the first power source 16 to the outlet 24 located in the vehicle 26, as indicated by the dotted lines, with the power from the first power source 16 being routed to the on-board charging control module 18, as indicated by the dashed lines. In cases where the first power source 16 provides a power of 240 volts, the AC / AC converter 48 steps down the power, being able to control the waveform of the power signal to provide 120 volts at the outlet 24, as shown in Fig. Figure 3 shows that the user can supply power to an electronic device while the vehicle 26 is being charged. In particular, the user can draw power directly from the first power source 16 while the battery 14 is being charged. In cases where the first power source 16 provides 120 volts, the AC / AC converter 48 can be bypassed, as shown in Figure 3. Fig. Figure 4 shows that the user can supply power to an electronic device while the vehicle 26 is being charged. In particular, the user can draw power directly from the first power source 16 while the battery 14 is being charged. In both cases, the splitter module 22 can also be configured to modify the power signal waveform to a predefined waveform.

Claims

[1] Power control system (10) for providing power to a load and a battery (14) from a first power source (16), wherein the first power source (16) transmits electrical power in the form of an alternating current, the power control system (10) comprising: an on-board charging control module (18) which includes a first processing unit (20) configured to process the electrical power from the first power source (16) to charge the battery (14); and a splitter module (22) inserted between the first power source (16) and the on-board charging control module (18), wherein the splitter module (22) directs electrical power from the first power source (16) to the load; characterized by , that the splitter module (22) contains an AC / AC converter (48) and a sensing unit (60) configured to measure a value of current and / or voltage; wherein the splitter module (22) includes a switch (64) which can be actuated to bypass or switch on the AC / AC converter (48) and a second processing unit (62) wherein the second processing unit (62) receives the measured value of the current and / or voltage to actuate the switch (64). [2] Power control system (10) according to claim 1, wherein the on-board charging control module (18) is configured to provide galvanic isolation between the load and the battery (14). [3] Power control system (10) according to claim 1, wherein the splitter module (22) is configured to change a voltage of the electrical power. [4] Power control system (10) according to claim 1, wherein the second processing unit (62) is further configured to actuate the AC / AC converter (48) to generate a predetermined signal shape. [5] Power control system (10) according to claim 4, wherein the first processing unit (20) of the on-board charging control module (18) transmits the charging information of the battery (14) to the second processing unit (62) of the AC / AC converter (48), wherein the second processing unit (62) processes the charging information to control the switch (64) and maintain the target signal shape. [6] Power control system (10) according to claim 1, wherein the AC / AC converter (48) is a step-down converter or a step-up / step-down converter or a single-ended primary inductor converter. [7] Power control system (10) according to claim 1, wherein the on-board charging control module (18) and the splitter module (22) are integrated as a single module.

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