Integrated power generation device capable of independently charging and discharging each of plurality of battery modules, and integrated power generation system for range-extended electric vehicle including same

Abstract

The present disclosure relates to an integrated power generation device and an integrated power generation system for a range-extended electric vehicle and, more specifically, to an integrated power generation device capable of independently charging and discharging each of first to N-th battery modules (herein, N is a natural number greater than 1), the integrated power generation device comprising: a generator having first to N-th stator windings; and first to N-th power conversion modules, which have sides connected to the first to N-th stator windings, respectively, and have the other sides connected to the first to N-th battery modules, respectively, wherein the generator has a structure in which a stator winding connected to an i-th power conversion module, which is one of the first to N-th power conversion modules, and a stator winding connected to a j-th power conversion module, which is another one of the first to N-th power conversion modules, are insulated from each other, and the first to N-th power conversion modules independently charge and discharge the first to N-th battery modules, respectively.

Description

An integrated power generation device capable of independently charging and discharging each of multiple battery modules and an integrated power generation system for an electric vehicle with extended range including the same.

[0001] The present disclosure relates to an integrated power generation device and an integrated power generation system for a range-extending electric vehicle, and more particularly, to an integrated power generation device capable of performing battery cell balancing of a battery included in a range-extending electric vehicle using a generator with each phase insulated and a plurality of power conversion modules, and an integrated power generation system for a range-extending electric vehicle including the same.

[0002]

[0003] Electric vehicles (EVs) are steadily growing in the automotive industry due to their zero emissions and high fuel efficiency. However, their driving range is heavily dependent on battery capacity, and when the battery runs out, driving is limited in environments with limited charging infrastructure. To address this issue, range-extended electric vehicles (REEVs) are being developed.

[0004] Extended-range electric vehicles (EVs) are equipped with both a battery and an internal combustion engine. While maintaining the basic function of an electric vehicle, the engine acts as a generator to recharge the battery when its charge depletes during driving, extending its range. This approach compensates for the short range of EVs, a drawback of EVs, while maintaining environmental friendliness by using the battery as the primary power source.

[0005] A key component in extended-range electric vehicles is the battery, which is comprised of multiple cells in a module form and multiple modules in a battery pack. Cell voltage balancing is essential to optimizing battery performance and lifespan. When multiple cells are connected in series, voltage imbalances between cells are a critical issue. Overcharging can lead to explosion, while overdischarging can damage the electrodes and render the battery inoperable. Therefore, cell voltage balancing is essential to prevent explosions and ensure maximum charging and discharging capacity.

[0006] Traditionally, battery cell balancing was achieved by adjusting the voltage between cells using a converter. However, this method required a separate converter device for the sole purpose of battery cell balancing, which increased manufacturing costs and system control complexity. This problem also persists in range-extending electric vehicles, and can be further complicated by the need for simultaneous management of the engine and battery.

[0007] Therefore, a more efficient and simplified voltage balancing technology between cells and modules suitable for extended range electric vehicles is required.

[0008] (National Project) Development of an 8KW powertrain using no rare earth elements for electric motorcycles

[0009] (Assignment number) 00228687

[0010] (Assignment Period) 23.4.20 - 27.4.19

[0011]

[0012] The present disclosure has been made to solve the above-mentioned problems, and the purpose of the integrated power generation device and the integrated power generation system for a range-extending electric vehicle according to the present disclosure is to provide an integrated power generation device and an integrated power generation system for a range-extending electric vehicle, which insulate the windings of a generator equipped in a range-extending electric vehicle from each other, provide a power conversion module between each winding and a battery module, and utilize the power conversion module for the generator for battery cell balancing, thereby reducing the manufacturing cost and miniaturizing the volume of the equipment by not installing a separate battery cell balancing device.

[0013]

[0014] In order to solve the above-described problem, the integrated power generation system according to the present disclosure is an integrated power generation device capable of independently charging and discharging first to N battery modules (wherein N is a natural number greater than 1), comprising a generator having first to N stator windings and first to N power conversion modules, one side of which is respectively connected to the first to N stator windings and the other side of which is respectively connected to the first to N battery modules, wherein the generator has a structure in which a stator winding connected to an i-th power conversion module, which is any one of the first to N power conversion modules, and a stator winding connected to a j-th power conversion module, which is any other one of the first to N power conversion modules, are insulated from each other, and each of the first to N power conversion modules independently charges and discharges each of the first to N battery modules.

[0015] Additionally, each of the first to N stator windings is a single-phase winding electrically insulated from each other.

[0016] Additionally, the first to N stator windings are wound in a concentrated manner on the teeth of consecutive multiples of three stators so that a three-phase winding set is formed.

[0017] Additionally, the i-th power conversion module, which is one of the first to N power conversion modules, includes an H-bridge converter.

[0018] In addition, each of the i-th and j-th power conversion modules connected to the i-th stator winding, which is one of the first to N-th stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, controls the phase currents so that the phase currents flowing in the i-th and j-th stator windings have a phase difference of (360 / N)° when in the starting motor mode for starting an engine connected to the generator using the generator.

[0019] In addition, each of the i-th and j-th power conversion modules connected to each of the i-th stator winding, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, controls each phase current such that the phase and magnitude of the phase current of the i-th power conversion module and the phase and magnitude of the phase current of the j-th power conversion module are independent of each other when in a power generation mode in which power is generated using the generator after an engine connected to the generator is started or in a battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged.

[0020] In addition, each of the i-th and j-th power conversion modules connected to each of the i-th stator windings, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, controls the phase currents of the i-th and j-th power conversion modules so that the phase difference of the phase currents is (360 / N)° when in a power generation mode in which power is generated using a generator after an engine connected to the generator is started, or in a battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged, and the magnitudes of the phase currents are controlled independently of each other.

[0021] Additionally, each of the first to N stator windings is a three-phase winding electrically insulated from each other.

[0022] Additionally, the i-th power conversion module, which is one of the first to N power conversion modules, includes a three-phase PWM converter.

[0023] In addition, each of the i-th and j-th power conversion modules connected to the i-th stator winding, which is one of the first to N-th stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, controls the phase currents such that the three-phase phase currents of the i-th stator winding and the three-phase phase currents of the j-th stator winding have a phase difference of (360 / N)° when in the starting motor mode for starting an engine connected to the generator using the generator.

[0024] In addition, the i-th power conversion module, which is one of the first to N power conversion modules, controls the input and output current of the i-th power conversion module based on a command from a BMS that manages the i-th battery module connected to the i-th power conversion module among the first to N battery modules, when the i-th power conversion module is in a power generation mode in which power is generated using a generator after the engine is started or in a battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged.

[0025] In addition, the generator includes a generator case that houses a stator, a rotor, and first to N power conversion modules therein, and each of the first to N power conversion modules is provided on a first PCB to an M-th PCB (wherein M is a natural number, and M≥N), and the first to M PCBs are stacked and housed inside the generator case.

[0026] In order to solve the above-described problems, the present disclosure provides an integrated power generation system for an electric vehicle with an extended range, including a power generation engine, a vehicle controller, first to N battery modules, and a BMS, wherein the integrated power generation system includes an integrated power generation device having the characteristics of claim 1 and a power generation device controller that controls the integrated power generation device in conjunction with the vehicle controller and the BMS, wherein the power generation device controller generates a torque command for a generator and a charge / discharge command for each of the first to N battery modules based on at least one of a voltage, a SOC, and a temperature of the first to N battery modules, thereby controlling the generator and the first to N power conversion modules included in the integrated power generation device.

[0027] Additionally, the power generation device controller controls the generator and the first to N power conversion modules included in the integrated power generation device so that the voltages or SOCs of the first to N battery modules become the same.

[0028] In addition, the power generation device controller calculates the sum (Pc_sum) of the charging power required for each of the first to N battery modules, and if Pc_sum is greater than 0, sets the torque command to a negative value so that the generator can operate in the generation mode, and if Pc_sum is less than 0, sets the torque command to a positive value so that the generator can operate in the driving mode, but sets the torque command to a value within the allowable torque range according to the power generation engine status.

[0029]

[0030] According to one embodiment of the present disclosure, a battery cell balancing operation can be performed only with a power conversion module connected to a generator without a separate battery cell balancing circuit, so that the manufacturing cost of a system for battery maintenance can be significantly reduced and the integrated power generation device can be made compact and lightweight.

[0031] Figure 1 is a schematic diagram of an integrated power generation device according to one embodiment of the present disclosure.

[0032] Figure 2 is a circuit diagram of an integrated power generation device according to the first embodiment of the present disclosure.

[0033] Figure 3 is a circuit diagram of an integrated power generation device according to the first and second embodiments of the present disclosure.

[0034] Fig. 4 is a cross-sectional view of a generator according to the first embodiment of the present disclosure.

[0035] Fig. 5 is a winding diagram of a stator winding according to the first embodiment of the present disclosure.

[0036] Fig. 6 is a circuit diagram of an integrated power generation device according to a second embodiment of the present disclosure.

[0037] Fig. 7 is a cross-sectional view of a generator according to a second embodiment of the present disclosure.

[0038] Fig. 8 is a winding diagram of a stator winding according to the second embodiment of the present disclosure.

[0039] FIG. 9 illustrates a PCB of a power conversion module according to an embodiment of the present disclosure.

[0040] Figure 10 illustrates the PCB of the power conversion module being inserted into the generator case.

[0041] FIG. 11 is a schematic diagram of a power conversion module controller according to an embodiment of the present disclosure.

[0042] Fig. 12 is a schematic diagram of an integrated power generation system for an electric vehicle with an extended range according to one embodiment of the present disclosure.

[0043]

[0044] The purpose, features, and advantages of the present disclosure described above will become more apparent through the following examples taken in conjunction with the accompanying drawings. The specific structural and functional descriptions below are merely illustrative for the purpose of explaining embodiments according to the concept of the present disclosure, and embodiments according to the concept of the present disclosure may be implemented in various forms and should not be construed as limited to the embodiments described in this specification or application. Since embodiments according to the concept of the present disclosure may have various modifications and may take various forms, specific embodiments are illustrated in the drawings and described in detail in this specification or application. However, this is not intended to limit embodiments according to the concept of the present disclosure to specific disclosed forms, but should be understood to include all modifications, equivalents, and substitutes included in the spirit and technical scope of the present disclosure. Terms such as first and / or second may be used to describe various components, but the components are not limited to the terms. Terms are used solely for the purpose of distinguishing one component from another, for example, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component, without departing from the scope of the rights according to the concept of the present disclosure. When a component is referred to as being connected or coupled to another component, it should be understood that it may be directly connected or coupled to that other component, but there may also be other components in between. Conversely, when a component is referred to as being directly connected or coupled to another component, it should be understood that there are no other components in between. Other expressions used to describe the relationship between components, such as "between" and "directly between" or "adjacent to" and "directly adjacent to", should be interpreted similarly.The terminology used herein is used only to describe specific embodiments and is not intended to limit the present disclosure. The singular expression includes the plural expression unless the context clearly dictates otherwise. It should be understood that the terms "comprise" or "have" used herein indicate the presence of a described feature, number, step, operation, component, part, or combination thereof, but do not preclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof. Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning they have in the context of the relevant technology, and shall not be interpreted in an idealized or overly formal sense unless explicitly defined herein. Hereinafter, the present disclosure will be described in detail by describing a preferred embodiment of the present disclosure with reference to the accompanying drawings. The same reference numerals in each drawing represent the same parts.

[0045] Hereinafter, with reference to the attached drawings, a preferred embodiment of an integrated power generation device (1) and an integrated power generation system (3) for an extended range electric vehicle according to the present disclosure will be described in detail.

[0046] [Integrated Power Generation Unit (1)]

[0047] Figure 1 is a schematic diagram of an integrated power generation device (1) according to one embodiment of the present disclosure.

[0048] An integrated power generation device (1) according to one embodiment of the present disclosure independently charges and discharges each of the first to N battery modules (200-1 to 200-N). Here, N is a natural number greater than 1. Specifically, an integrated power generation device (1) according to one embodiment of the present disclosure performs the role of a starting motor of an engine coupled with a generator, or, when the generator produces power, charges the first to N battery modules (200-1 to 200-N) from the generator, or independently controls the first to N power conversion modules to charge or discharge each of the first to N battery modules (200-1 to 200-N) so that the voltages of the first to N battery modules (200-1 to 200-N) become uniform, thereby performing a battery cell balancing operation.

[0049] Here, each of the first to N battery modules (200-1 to 200-N) includes at least one battery cell. The battery cell performs a charging operation that converts electrical energy from the outside into chemical energy and stores it, and a discharging operation that converts the stored chemical energy into electrical energy and provides it to the outside. For example, the battery cell may be any one of a lithium-ion battery, a lithium polymer battery, a nickel-metal hydride (NiMH), a nickel-cadmium (NiCd), a lead-acid battery, and a lithium titanate (LTO).

[0050] An integrated power generation device (1) according to an embodiment of the present disclosure includes at least one BMS (Battery Management System) that manages each of the first to N battery modules (200-1 to 200-N). The BMS monitors and manages battery cells included in each battery module it manages, controls charging and discharging of the battery modules, manages the heat of the battery modules so that the temperature of the battery modules is maintained at an appropriate level so that the batteries can exhibit optimal performance, performs a battery cell balancing operation so that the battery cells have a uniform voltage, and can perform a battery module status management operation that calculates the status of the battery modules, such as a State of Charge (SOC), a State of Health (SOH), and a State of Power (SOP). The BMS is typically provided separately from the first to N battery modules (200-1 to 200-N), but as an example, each of the first to N battery modules (200-1 to 200-N) may include a BMS.

[0051] Here, one side of the first to Nth battery modules (200-1 to 200-N) is connected to the first to Nth power conversion modules (120-1 to 120-N), respectively, and the other side is connected in series with different battery modules and is connected to a PDU (Power Distribution Unit).

[0052] The PDU (Power Distribution Unit) distributes power output from the 1st to Nth battery modules (200-1 to 200-N) to loads other than the integrated power generation device (1) of the present disclosure.

[0053] An inverter is installed between the PDU and the motor, receiving power from the PDU and generating three-phase power to drive the motor. This allows the motor to be driven by the inverter. When an integrated power generation unit (1) is installed in a vehicle, the motor can be connected to the power system and drive the vehicle.

[0054] An on-board charger (OBC) is installed between the PDU and the grid, receives power from the grid, and charges the first to Nth battery modules (200-1 to 200-N) through the PDU. When the integrated power generation device (1) of the present disclosure is mounted on a vehicle, the OBC may also be mounted on the vehicle. The OBC and the grid may be connected via a detachable terminal, such as a charging port or receptacle.

[0055] Next, an integrated power generation device (1) according to an embodiment of the present disclosure will be described. The integrated power generation device (1) according to the present disclosure aims to perform battery cell balancing of the first to N battery modules (200-1 to 200-N) using only the first to N power conversion modules (120-1 to 120-N) connected to the generator (110) without installing a separate battery cell balancing circuit. To this end, the integrated power generation device (1) according to an embodiment of the present disclosure includes the generator (110) and the first to N power conversion modules (120-1 to 120-N).

[0056] The generator (110) has first to N stator windings (111-1 to 111-N). Referring to FIG. 1, the generator (110) has first to N stator windings (111-1 to 111-N), and the first to N stator windings (111-1 to 111-N) are connected to first to N power conversion modules (120-1 to 120-N), respectively.

[0057] In addition, the generator (110) has a structure in which an i-th stator winding connected to an i-th power conversion module, which is one of the first to N power conversion modules (120-1 to 120-N), and a j-th stator winding connected to a j-th power conversion module, which is another one of the first to N power conversion modules (120-1 to 120-N), are insulated from each other. Specifically, referring to FIG. 1, a first stator winding (111-1) connected to a first power conversion module (120-1) and a second stator winding (111-2) connected to a second power conversion module (120-2) have a structure in which they are insulated from each other rather than having a structure in which they are connected to a neutral point, and the second stator winding (111-2) and the third stator winding (111-3) are also insulated from each other. Through this, each stator winding is not electrically influenced by the other, so that charging and discharging operations for battery cell balancing operations can be performed separately for each stator winding.

[0058] The first to N power conversion modules (120-1 to 120-N) have one end connected to the first to N stator windings (111-1 to 111-N), respectively, and the other end connected to the first to N battery modules (200-1 to 200-N), respectively. Here, the first to N power conversion modules (120-1 to 120-N) each independently charge and discharge the first to N battery modules (200-1 to 200-N), respectively. In addition, the first to N power conversion modules (120-1 to 120-N) each are insulated from each other, similar to the first to N stator windings (111-1 to 111-N). The specific circuit structure and control method of the first to N power conversion modules (120-1 to 120-N) will be described later.

[0059] Through this, since the battery cell balancing operation can be performed only with the power conversion module connected to the generator (110) without having a separate battery cell balancing circuit, the manufacturing cost of the system for battery maintenance is greatly reduced, and the integrated power generation device (1) is made compact and lightweight.

[0060] Next, an embodiment of the integrated power generation device (1) of the present disclosure will be described.

[0061] The first to Nth power conversion modules (120-1 to 120-N) may have different circuit structure embodiments depending on whether the generator (110) is single-phase or three-phase. The case where the generator (110) is single-phase is described as the first embodiment, and the case where the generator (110) is three-phase is described as the second embodiment.

[0062] [Example 1]

[0063] In the integrated power generation device (1) according to the first embodiment of the present disclosure, each of the first to N stator windings (111-1 to 111-N) is a single-phase winding that is electrically insulated from each other. When the generator (110) has a total of N phases, the generator (110) includes the first to N stator windings (111-1 to 111-N), and each of the stator windings is insulated from each other and may be a single phase. In this case, the first to N power conversion modules (120-1 to 120-N) may have two embodiments, that is, embodiments 1-1 and 1-2.

[0064] [Example 1-1]

[0065] Figure 2 is a circuit diagram of an integrated power generation device (1) according to the first embodiment of the present disclosure.

[0066] The i-th power conversion module, which is one of the first to N power conversion modules (120-1 to 120-N) of the integrated power generation device (1) according to the first embodiment of the present disclosure, includes a rectifier and a discharge resistor module.

[0067] The rectifier has an AC terminal and a DC terminal connected to the i-th stator winding and the i-th battery module, respectively, and converts AC to DC. For example, the rectifier is a totem pole rectifier including a plurality of diodes and a plurality of switch elements. Specifically, referring to Fig. 2, the totem pole rectifier includes first and second switches (Q1, Q2), and first and second diodes (D1, D2). Q1 and Q2 are connected in series to form a totem pole circuit, and D1 and D2 are connected in series to form a totem pole circuit, and D1 and D2 are connected in parallel.

[0068] In addition, a first inductor may be provided between the i-th stator winding and the rectifier, and a capacitor (C1) may be connected to the DC terminal of the rectifier. Through this, since the totem pole rectifier includes Q1 and Q2, the power factor of the i-th power conversion module can be controlled to a unit power factor of 1 by switching control of Q1 and Q2. Therefore, the reactive power can be minimized, and the power conversion efficiency of the rectifier can be maximized.

[0069] The discharge resistor module is installed at the DC terminal of the rectifier and discharges the energy of the DC terminal of the rectifier according to the input control signal. Specifically, referring to Fig. 2, the discharge resistor module includes a first resistor, a third switch (Q3), and a third diode (D3). R1 ​​is connected in series with Q3, and D3 is connected in parallel with R1. Through this, by controlling Q3, the energy of the i-th battery module can be consumed through R1, thereby performing a discharge operation in cell balancing.

[0070] [Example 1-2]

[0071] Figure 3 is a circuit diagram of an integrated power generation device (1) according to the first-second embodiment of the present disclosure.

[0072] The i-th power conversion module, which is one of the first to N power conversion modules (120-1 to 120-N) of the integrated power generation device (1) according to the first to second embodiments of the present disclosure, includes an H-bridge converter. Specifically, referring to FIG. 3, the i-th power conversion module is the same as the first embodiment in that it includes a first inductor and a capacitor connected to the i-th stator winding, but the first embodiment includes a rectifier and a discharge resistor module, whereas the first embodiment includes an H-bridge converter. The H-bridge converter includes first to fourth switches (Q1 to Q4), and a first totem pole circuit including Q1 and Q2 and a second totem pole circuit including Q3 and Q4 are connected in parallel with each other.

[0073] The i-th power conversion module can control Q1 to Q4 in boost mode or buck mode. When operating in boost mode, current flows from the i-th stator winding toward the i-th battery module, thereby charging the i-th battery module. In addition, when operating in buck mode, current flows from the i-th battery module toward the i-th stator winding, thereby discharging the i-th battery module. The above control method can be independently performed in the first to N-th power conversion modules (120-1 to 120-N), and the voltages of each of the first to N-th battery modules (200-1 to 200-N) become the same, thereby performing battery cell balancing. For example, when the voltage of the i-th battery module is lower than or equal to a predetermined reference voltage, the i-th power conversion module can control Q1 to Q4 in boost mode to charge the i-th battery module. When the voltage of the i-th battery module exceeds a predetermined reference voltage, the i-th power conversion module can discharge the i-th battery module by controlling Q1 to Q4 in buck mode.

[0074] In this way, in the first and second embodiments, since the i-th power conversion module includes an H-bridge converter, current can flow in both directions between the i-th battery module and the i-th stator winding, and current can be controlled at unit power factor through switch control during charging and discharging of the i-th battery module.

[0075] [Power conversion module control method of the first embodiment]

[0076] Next, a method for controlling the first to N power conversion modules (120-1 to 120-N) for each mode in the first embodiment is described.

[0077] The first to Nth power conversion modules (120-1 to 120-N) can be controlled in three modes: starter motor mode, power generation mode, and battery cell balancing mode.

[0078] First, let's explain the starter motor mode.

[0079] The starter motor mode refers to a mode for driving a generator (110) connected to the engine shaft as a starter motor to start the engine.

[0080] More specifically, regarding the engine, for example, when the integrated power generation device (1) is mounted on a hybrid vehicle, the engine connected to the generator (110) by a shaft may be an engine connected to the power system of the hybrid vehicle. Furthermore, when the integrated power generation device (1) is mounted on a range-extending electric vehicle, the engine connected to the generator (110) by a shaft may be separated from the power system for driving the vehicle and may be a power generation engine solely for supplying power to the generator (110).

[0081] Each of the i-th and j-th power conversion modules connected to the i-th stator winding, which is one of the first to N-th stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, controls the phase currents so that the phase currents flowing in the i-th and j-th stator windings have a phase difference of (360 / N)° when in the starting motor mode for starting an engine connected to the generator using the generator. For example, referring to FIGS. 2 and 3, in the starting motor mode, the first and second power conversion modules (120-1, 120-2) whose stator windings are adjacent to each other control the phase currents so that the phase currents flowing in the first and second stator windings (111-1, 111-2) have a phase difference of (360 / N)°, thereby forming a rotating magnetic field in the gap of the generator (110). Likewise, the second and third stator windings (111-2, 111-3) can be controlled to generate a phase difference in the phase current as described above, and in this case, the generator (110) rotates and can ultimately operate as a starting motor of an engine connected to the shaft of the generator (110).

[0082] In this way, when the generator (110) is driven in starter motor mode to start the engine, a separate starter motor does not need to be installed for the engine, so the manufacturing cost of the power generation system is reduced and the system size is made compact and lightweight.

[0083] Next, the power generation mode and battery cell balancing mode are explained.

[0084] The power generation mode refers to a mode in which the generator (110) receives power from the engine after the engine is started and collectively controls the first to N power conversion modules (120-1 to 120-N) to charge the first to N battery modules (200-1 to 200-N). In addition, the battery cell balancing mode refers to a mode in which the first to N power conversion modules (120-1 to 120-N) are independently controlled to individually charge or discharge the first to N battery modules (200-1 to 200-N) connected to each of the first to N power conversion modules (120-1 to 120-N).

[0085] There are two embodiments (embodiments 1-3 and 1-4) for controlling the first to N power conversion modules (120-1 to 120-N) in the power generation mode and battery cell balancing mode.

[0086] [Example 1-3]

[0087] Next, examples 1-3 will be described.

[0088] The i and j power conversion modules control their respective phase currents such that the phase and magnitude of the phase current of the i power conversion module and the phase and magnitude of the phase current of the j power conversion module are independent of each other when in the power generation mode in which the engine is started and the battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged. For example, referring to FIGS. 2 and 3, in the power generation mode and the battery cell balancing mode, the first and second power conversion modules having adjacent stator windings can control their respective phase currents such that the phase and magnitude of the phase current flowing in the first stator winding and the phase and magnitude of the phase current flowing in the second stator winding have independent values.

[0089] That is, since there are differences in the voltage, current, SOC, SOH, etc. of the first to Nth battery modules (200-1 to 200-N), the phase and magnitude of the phase current of the i and jth power conversion modules can be independently controlled in the power generation mode and battery cell balancing mode to supply or discharge appropriate power to the first to Nth battery modules (200-1 to 200-N), thereby performing battery cell balancing.

[0090] [Example 1-4]

[0091] Next, examples 1-4 will be described.

[0092] As described above, the first to N power conversion devices are independently controlled to perform battery cell balancing operation on the entire first to N battery modules (200-1 to 200-N) via the generator (110). However, when one of the first to N battery modules (200-1 to 200-N) is referred to as an i-th battery module and the other is referred to as a j-th battery module, there is a problem that torque ripple occurs in the generator (110) in each of the i-th and j-th stator windings during the process in which the generator (110) charges the i-th battery module and discharges the j-th battery module. Therefore, in order to solve this problem, the first to fourth embodiments control the phase currents flowing in the first to N stator windings (111-1 to 111-N) to have a predetermined phase difference from each other.

[0093] Specifically, in the first to fourth embodiments, the i and j power conversion modules control the phase currents of the i and j power conversion modules so that the phase difference between the phase currents is (360 / N)° when the engine is in the power generation mode in which the generator is used for generating power after the engine is started or the battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged, and the magnitudes of the phase currents are controlled independently of each other. For example, referring to FIGS. 2 and 3, in the power generation mode and the battery cell balancing mode, the first and second power conversion modules having adjacent stator windings control the phase currents so that the phase difference between the phase currents flowing through the first and second stator windings is (360 / N)°, and the magnitudes of the phase currents are independently controlled in the first and second power conversion modules so that the magnitude values ​​of the phase currents are different from each other.

[0094] In this case, since the first to Nth power conversion modules (120-1 to 120-N) are controlled to have a predetermined phase difference as in the starting motor mode, noise during operation of the generator (110) due to torque ripple can be suppressed, and at the same time, there is an effect of performing battery cell balancing by supplying or discharging appropriate power to the first to Nth battery modules (200-1 to 200-N) as in the power generation mode and battery cell balancing mode.

[0095] The control methods of the above-described embodiments 1-3 and 1-4 can be applied to the first to N power conversion circuits of the embodiments 1-1 and 1-2, respectively.

[0096] [Structure of generator (110) of the first embodiment]

[0097] FIG. 4 is a cross-sectional view of a generator (110) according to the first embodiment of the present disclosure, and FIG. 5 is a winding diagram of a stator winding according to the first embodiment of the present disclosure.

[0098] FIGS. 4 and 5 illustrate a case where N is 6, and since the i-th stator winding, which is one of the first to sixth stator windings, includes a single-phase winding, the generator (110) according to the first embodiment of the present disclosure has a total of 6 phases.

[0099] A generator (110) of a first embodiment of the present disclosure includes a stator (112) and a rotor (113). Specifically, referring to FIG. 4, the stator (112) and the rotor (113) are illustrated. The stator (112) includes a cylindrical yoke (1121) and a plurality of teeth (1122) extending toward the center of the yoke (1121). Slots are formed between the teeth (1122) and first to N stator windings (111-1 to 111-N) as illustrated in FIG. 5 are wound around each tooth (1122). The rotor (113) includes a cylindrical core (1131) and a plurality of permanent magnets attached to an outer surface of the core (1131).

[0100] The first to N stator windings (111-1 to 111-N) of the integrated power generation device (1) according to the first embodiment of the present disclosure are wound in a concentrated manner on teeth (1122) of consecutive multiples of 3 stators (112) so as to form a three-phase winding set. For example, referring to FIGS. 4 and 5 , when N is 6, the generator (110) according to the first embodiment of the present disclosure may be a six-phase, four-pole generator (110) including a rotor (113) having four permanent magnets and a stator (112) having 12 slots. Here, the stator (112) may be designed so that the number of slots per pole is 0.5.

[0101] Specifically, referring to FIGS. 4 and 5, when N is 6, the integrated power generation device (1) includes first to sixth power conversion modules connected to first to sixth stator windings and first to sixth stator windings (111-1 to 6), respectively. For example, referring to FIG. 5, the first stator winding (111-1) may be an A winding and an A' winding connected to each other. Similarly, the second stator winding (111-2) may be a B and a B' winding connected to each other, the third stator winding (111-3) may be a C and a C' winding connected to each other, the fourth stator winding (111-4) may be a D and a D' winding connected to each other, the fifth stator winding (111-5) may be an E and an E' winding connected to each other, and the sixth stator winding (111-6) may be an F and an F' winding connected to each other. The windings included in each stator winding can be wound at a predetermined angle on each tooth (1122).

[0102] A plurality of permanent magnets may be provided on the outer surface of the rotor (113). Each permanent magnet may be arranged so that the N pole and the S pole alternately face from the rotor (113) toward the stator (112). For example, referring to FIG. 4, when a permanent magnet whose pole in the direction from the rotor (113) to the stator (112) is the N pole is referred to as a N pole permanent magnet (1132), and a permanent magnet whose pole in the direction from the rotor (113) to the stator (112) is the S pole is referred to as a S pole permanent magnet (1133), two N pole permanent magnets (1132) and two S pole permanent magnets (1133) are alternately attached to the outer surface of the rotor (113).

[0103] As described above, there is an effect of forming the stator (112) and rotor (113) of the generator (110) applied to the first embodiment to more stably generate starting torque.

[0104] [Example 2]

[0105] Fig. 6 is a circuit diagram of an integrated power generation device (1) according to the second embodiment of the present disclosure.

[0106] In the integrated power generation device (1) according to the second embodiment of the present disclosure, each of the first to N stator windings (111-1 to 111-N) is a three-phase winding that is electrically insulated from each other. Specifically, referring to FIG. 6, one end of the three-phase windings A, B, and C included in the first to N stator windings (111-1 to 111-N) is connected to each other to form a neutral point, and the first to N stator windings (111-1 to 111-N) are electrically insulated from each other. Through this, the first to N stator windings (111-1 to 111-N) can operate independently of each other to perform battery cell balancing of the first to N battery modules (200-1 to 200-N).

[0107] An i-th power conversion module among the first to N-th power conversion modules (120-1 to 120-N) includes a three-phase PWM converter. Specifically, referring to FIG. 6, the three-phase PWM converter includes first to sixth switches (Q1 to Q6), a three-phase inductor (L2), and a capacitor (C1). Q1 to Q6 form a three-phase inverter circuit. One side of the three-phase inductor is connected to the i-th stator winding, and the other side is connected to the three-phase inverter circuit. The three-phase inductor (L2) includes three inductors connected to each of the three phases, one side of each inductor is connected to each of the three-phase windings of the i-th stator winding, and the other side of each inductor is connected to a common node between two switches included in the three-phase inverter circuit. The capacitor (C1) is connected to an output terminal of the three-phase inverter circuit.

[0108] Therefore, the circuit topology of the three-phase inductor (L2) and the three-phase inverter is identical to three coupled buck-boost circuits for the ith stator winding, which provides the effect of transmitting current in both directions. In addition, even if the ith stator winding includes a three-phase winding, the ith power conversion module can be configured as described above to perform charging and discharging for the ith battery module, thereby providing the effect of enabling battery cell balancing operation.

[0109] [Power conversion module control method of the second embodiment]

[0110] Next, a method for controlling the first to N power conversion modules (120-1 to 120-N) for each mode in the second embodiment is described.

[0111] The first to Nth power conversion modules (120-1 to 120-N) can be controlled in three modes, namely, a starter motor mode, a power generation mode, and a battery cell balancing mode, as in the first embodiment. Since the starter motor mode, power generation mode, and battery cell balancing mode are the same as those described in the first embodiment, a detailed description thereof will be omitted.

[0112] First, let's explain the starter motor mode.

[0113] Each of the i-th and j-th power conversion modules (120-1 to 120-N) connected to each of the i-th stator windings (111-1 to 111-N) and the j-th stator windings arranged adjacent to the i-th stator windings controls the phase currents so that the three-phase phase currents of the i-th stator winding and the three-phase phase currents of the j-th stator winding have a phase difference of (360 / N)° when the engine connected to the generator (110) is in the starting motor mode using the generator (110).

[0114] For example, referring to FIG. 6, in the case of the starting motor mode, the first and second power conversion modules (120-1, 120-2) having adjacent stator windings control the phase currents flowing in the first and second stator windings (111-1, 111-2) so that the phase of the phase currents becomes (360 / N)°, thereby forming a rotating magnetic field in the gap of the generator (110). Similarly, the second and third stator windings (111-2, 111-3) can also be controlled so that a phase difference occurs in the phase currents as described above, and in this case, the generator (110) rotates, and ultimately can operate as a starting motor of an engine connected to the shaft of the generator (110).

[0115] In this way, when the generator (110) is driven in starter motor mode to start the engine, a separate starter motor does not need to be installed for the engine, so the manufacturing cost of the power generation system is reduced and the system is made compact and lightweight. In addition, when the current of adjacent windings is controlled to have a phase difference of a predetermined angle, the load torque becomes constant, which has the effect of reducing noise caused by torque ripple when the generator (110) is driven.

[0116] Next, the power generation mode and battery cell balancing mode are explained.

[0117] The i-th power conversion module, which is one of the first to N power conversion modules (120-1 to 120-N), controls the input and output current of the i-th power conversion module based on a command of a BMS included in the i-th battery module connected to the i-th power conversion module among the first to N battery modules (200-1 to 200-N), when the i-th power conversion module is in a power generation mode in which power is generated using a generator (110) after the engine is started or in a battery cell balancing mode in which at least one of the first to N battery modules (200-1 to 200-N) is charged and discharged.

[0118] Specifically, when any one of the first to Nth power conversion modules (120-1 to 120-N) is referred to as an i-th power conversion module, the i-th power conversion module receives a command from a BMS included in an i-th battery module, and controls the i-th power conversion module based on the command from the BMS to perform charging and discharging on a battery cell included in the i-th battery module.

[0119] For example, when the voltage of a battery cell included in the i-th battery module is lower than the reference voltage, the BMS included in the i-th power conversion module instructs the i-th power conversion module to perform a charging operation for battery cell balancing, and the i-th power conversion module controls the current from the i-th stator winding toward the i-th battery module, so that the i-th battery module is charged.

[0120] Conversely, if the voltage of the battery cell included in the i-th battery module exceeds the reference voltage, the BMS included in the i-th power conversion module instructs the i-th power conversion module to perform a discharge operation for battery cell balancing, and the i-th power conversion module controls the current in the i-th battery module in the direction of the i-th stator winding, thereby causing the i-th battery module to discharge.

[0121] The i-th power conversion module according to the second embodiment of the present disclosure further includes an auxiliary switch (SWa) provided between the neutral point of the i-th stator winding and the DC negative terminal of the three-phase PWM converter, and selectively connecting or disconnecting the neutral point of the i-th stator winding and the DC negative terminal.

[0122] Next, the operation of the auxiliary switch (SWa) for each operation mode of the i power conversion module is described.

[0123] In the case of the starter motor mode for starting an engine connected to the generator (110) using the generator (110), the auxiliary switches (SWa) of each of the first to N power conversion modules (120-1 to 120-N) are turned off, and the three-phase PWM converter operates as an inverter. In this case, since the three-phase PWM converter operates as a normal inverter, current is applied to the first to N stator windings (111-1 to 111-N) to rotate the generator (110) as a starter motor.

[0124] In addition, in the case of power generation or battery cell balancing mode using a generator (110), the auxiliary switch (SWa) of each of the first to Nth power conversion modules (120-1 to 120-N) is turned on, and the three-phase PWM converter operates in coupled buck-boost. In this case, since the Samsung inductor connected to the i-th stator winding and the totem pole circuit of the three-phase PWM converter have a coupled buck-boost topology, the current can be controlled in both directions, thereby charging or discharging the i-th battery module.

[0125] For example, when one of the first to N stator windings (111-1 to 111-N) is referred to as an i-th stator winding and the other is referred to as a j-th stator winding, the i-th power conversion module is controlled to generate a load torque in the i-th stator winding in order to charge the i-th battery module. Simultaneously, the j-th power conversion module is controlled to generate a motoring torque in the j-th stator winding in order to discharge the j-th battery module. In this case, since the energy of the j-th battery module is transferred to the i-th battery module, battery cell balancing can be achieved between battery modules.

[0126] In this way, by controlling the auxiliary switch (SWa) according to the operation mode, the three-phase PWM converter can be operated as an inverter or a coupled buck-boost converter, so that a separate battery cell balancing circuit is not required, and the integrated power generation device (1) can be simplified and made lighter.

[0127] [Structure of the generator (110) of the second embodiment]

[0128] Fig. 7 is a cross-sectional view of a generator (110) according to the second embodiment of the present disclosure, and Fig. 8 is a winding diagram of a stator winding according to the second embodiment of the present disclosure.

[0129] FIGS. 7 and 8 illustrate a case where N is 4, and since the i-th stator winding, which is one of the first to fourth stator windings, includes a three-phase winding, the generator (110) according to the second embodiment of the present disclosure has a total of 12 phases.

[0130] A generator (110) of a second embodiment of the present disclosure includes a stator (112) and a rotor (113) similar to the first embodiment. Specifically, referring to FIG. 7, the stator (112) and the rotor (113) are illustrated. The stator (112) includes a cylindrical yoke (1121) and a plurality of teeth (1122) extending toward the center of the yoke (1121). Slots are formed between the teeth (1122) and first to N stator windings (111-1 to 111-N) as illustrated in FIG. 8 are wound around each of the teeth (1122). The rotor (113) includes a cylindrical core (1131) and a plurality of permanent magnets attached to an outer surface of the core (1131).

[0131] For example, referring to FIGS. 7 and 8, the generator (110) of the second embodiment of the present disclosure may be a 12-phase 8-pole generator (110) including a rotor (113) having 8 permanent magnets and a stator (112) having 12 slots when N is 4.

[0132] Referring to FIGS. 7 and 8, when N is 4, the integrated power generation device (1) includes first to fourth stator windings including three-phase windings and first to fourth power conversion modules respectively connected to the first to fourth stator windings. For example, referring to FIG. 8, the first stator winding (111-1) may be windings A1, B1, and C1 connected to each other. Similarly, the second stator winding (111-2) may be windings A2, B2, and C2 connected to each other, the third stator winding (111-3) may be windings A3, B3, and C3 connected to each other, and the fourth stator winding (111-4) may be windings A4, B4, and C4 connected to each other. As illustrated in FIG. 7, the three-phase windings may be wound on three teeth (1122) adjacent to each other.

[0133] A plurality of permanent magnets may be provided on the outer surface of the rotor (113). Each permanent magnet may be arranged so that the N pole and the S pole alternately face from the rotor (113) toward the stator (112). For example, referring to FIG. 7, when a permanent magnet whose pole in the direction from the rotor (113) to the stator (112) is the N pole is referred to as an N pole permanent magnet (1132), and a permanent magnet whose pole in the direction from the rotor (113) to the stator (112) is the S pole is referred to as an S pole permanent magnet (1133), four N pole permanent magnets (1132) and four S pole permanent magnets (1133) are alternately attached to the outer surface of the rotor (113).

[0134] As described above, there is an effect that can generate starting torque more stably by forming the stator (112) and rotor (113) of the generator (110) applied to the second embodiment.

[0135] [Laminated structure of the first to Nth power conversion modules (120-1 to 120-N)]

[0136] FIG. 9 illustrates a PCB of a power conversion module according to an embodiment of the present disclosure, and FIG. 10 illustrates a state in which the PCB of the power conversion module is inserted into a generator case (114).

[0137] Each of the first to Nth power conversion modules (120-1 to 120-N) is mounted on the first to Mth PCBs (122-1 to 122-M) (wherein, M is a natural number, and M≥N). Specifically, referring to FIG. 9, switches, capacitors, resistors, inductors, etc. included in the first to Nth power conversion modules (120-1 to 120-N) can be mounted and mounted on the circular first to Mth PCBs (122-1 to 122-M).

[0138] Usually, one power conversion module is generally installed on one PBC board, but if the sizes of the battery modules among the first to N battery modules (200-1 to 200-N) are different, the capacities of the first to N power conversion modules (120-1 to 120-N) also need to be designed differently. In this case, multiple power conversion modules may be installed on one PCB according to the capacity of the power conversion module, and conversely, one power conversion module may be installed on multiple PCBs. Specifically, M>N, and the p-th power conversion module, which is any one of the first to N power conversion modules (120-1 to 120-N), may be installed on multiple PCBs. In this case, the p-th power conversion module may be implemented on multiple PCBs connected in parallel to each other and provided in a stackable structure.

[0139] A generator (110) according to one embodiment of the present disclosure includes a generator case (114) and a generator shaft (115) that accommodate a stator (112), a rotor (113), and first to N power conversion modules (120-1 to 120-N) therein. Specifically, referring to FIG. 9, the generator case (1) is provided on one side of the rotor (113), and a generator shaft (115) is provided on the other side of the rotor (113). The generator shaft (115) can be coupled to an engine for the generator (110) so as to transmit rotational power thereto. In addition, the generator case (114) can accommodate the first to N power conversion modules (120-1 to 120-N), and can be coupled to the other side of the rotor (113) coaxially with the generator shaft (115).

[0140] The first to M PCBs (122-1 to 122-M) are stacked and accommodated inside the generator case (114). Referring to FIG. 10, the first to M PCBs (122-1 to 122-M) on which the first to N power conversion modules (120-1 to 120-N) are mounted are stacked coaxially with the generator case (114) in the direction of D1 and can be accommodated inside the generator case (114). In this way, since the first to M PCBs (122-1 to 122-M) are stacked and accommodated, space utilization is increased, and there is an effect of making the size of the integrated power generation device (1) of the present disclosure compact and lightweight.

[0141] However, in this specification and drawings, the generator case (114) and the first to M PCBs (122-1 to 122-M) are described and illustrated as having a circular shape, but the present disclosure is not limited thereto, and any shape of PCB that can have a polygonal shape and can be laminated can be adopted.

[0142] [Power Conversion Module Controller (121)]

[0143] Fig. 11 is a schematic diagram of a power conversion module controller (121) according to one embodiment of the present disclosure.

[0144] The i-th power conversion module, which is one of the first to N-th power conversion modules (120-1 to 120-N), includes a power conversion module controller (121). The power conversion module controller (121) receives various types of information from an external controller and a BMS included in the i-th battery module, and can control the current of the i-th power conversion device based on the information.

[0145] Referring to FIG. 11, the power conversion module controller (121) includes a current command generator (1211) and a current controller (1212).

[0146] The current command generator (1211) generates an output current command of the i-th power conversion module. Specifically, the current command generator (1211) generates an output current command based on at least one of the voltage and the SOC (State of Charge) of the i-th battery module, thereby controlling at least one switch included in the i-th power conversion module.

[0147] First, the current command generator (1211) can receive battery status information, which is information on the voltage, SOC (State of Charge), and temperature of the i-th battery module, from the BMS included in the i-th battery module. Thereafter, the current command generator (1211) determines whether to switch to the battery charging mode, which is the battery constant current charging mode or the battery constant voltage charging mode, based on the voltage and SOC (State of Charge) of the i-th battery module.

[0148] For example, the current command generator (1211) can output a constant current command (iL*) when in battery constant current charging mode. In addition, for example, the current command generator (1211) outputs a constant output voltage command (Vmod*) and a voltage controller output based on the output voltage of the i-th power conversion module as the current command (iL*) when in battery constant voltage charging mode. Through this, the current command generator (1211) can generate an appropriate current command depending on the state of the i-th battery module.

[0149] The current controller (1212) controls the output current of the ith power conversion module based on the output current command and the output current of the ith power conversion module. This uses a general PI-feedback control as illustrated in Fig. 11, and is a general current controller (1212) of a buck-boost converter. D_bias refers to the on-duty bias value of the switch included in the ith power conversion module, which is calculated based on the input voltage and output voltage of the ith power conversion module. Through this, there is an effect in which the current output from the current controller (1212) can accurately track the output current command of the ith power conversion module.

[0150] In addition, the power conversion module controller (121) can receive at least one of the rotation speed and torque information of the generator (110) from an external controller, and output the output current of the i-th power conversion module to control the generator (110) based thereon.

[0151] In addition, the power conversion module controller (121) can control the auxiliary switch (SWa) to turn on or off based on information or commands received from an external controller. Since the method for controlling the auxiliary switch (SWa) has been described above in connection with the second embodiment, a detailed description thereof will be omitted.

[0152] In addition, the power conversion module controller (121) can control the discharge resistor module of the first embodiment based on battery state information, which is information on the voltage, SOC (State of Charge), and temperature of the i-th battery module received from the BMS included in the i-th battery module. Specifically, the power conversion module controller (121) can control Q3 to be turned on so that the energy of the i-th battery module is discharged through R1 when the voltage of the input terminal of the i-th battery module is equal to or higher than a predetermined reference voltage based on the battery state information.

[0153] Here, the external controller may be a power generation device controller (310) to be described later, and the power generation device controller (310) will be described in detail below.

[0154] [Integrated Power Generation System for Extended-Range Electric Vehicles (3)]

[0155] Fig. 12 is a schematic diagram of an integrated power generation system (3) for an electric vehicle with an extended range according to one embodiment of the present disclosure.

[0156] Typically, a range-extended electric vehicle (REEV) is equipped with various devices such as a vehicle controller (500) that controls various devices mounted on the REEV, a power generation engine (400) that generates rotational energy, etc. However, a REEV is equipped with various devices, and when the integrated power generation device (1) of the present disclosure is mounted, the configuration is more complex than that of a conventional REEV, which presents a problem in that the complexity of control increases. Therefore, in order to organically control various devices mounted on the range-extended electric vehicle and the integrated power generation device (1) of the present disclosure, the integrated power generation system (3) for the range-extended electric vehicle of the present disclosure includes a power generation device controller (310). Specifically, referring to FIG. 12, an integrated power generation system (3) for an electric vehicle with an extended range according to an embodiment of the present disclosure includes an integrated power generation device (1), a power generation device controller (310), a power generation engine (400), a vehicle controller (500), and 1 to N battery modules (200-1 to 200-N) including a BMS according to an embodiment of the present disclosure.

[0157] More specifically, the power generation device controller (310) will be described.

[0158] The power generation device controller (310) controls the integrated power generation device (1) in conjunction with the vehicle controller (500) and the BMS. Specifically, the power generation device controller (310) controls the integrated power generation device (1) of the present disclosure through a linkage process in which information is shared between the vehicle controller (500) mounted on the vehicle and the BMS included in each of the first to N battery modules (200-1 to 200-N). To describe this in more detail, the power generation device controller (310) can transmit and receive status information on the power generation engine (400) and a control command for controlling the power generation engine (400) through the vehicle controller (500). In addition, the power generation device controller (310) can receive battery status information including at least one of voltage, SOC, and temperature of each of the first to N battery modules (200-1 to 200-N) from the BMS included in each of the first to N battery modules (200-1 to 200-N).

[0159] The vehicle controller (500) is connected to the power generation device controller (310) and can control the power generation engine (400). The function of the vehicle controller (500) is the same as that of the conventional vehicle controller (500), and only the differences are described in this specification.

[0160] Next, a method for controlling the integrated power generation device (1) by the power generation device controller (310) is described.

[0161] The power generation device controller (310) generates a torque command of the generator (110) and a charge / discharge command for each of the first to N battery modules (200-1 to 200-N) based on at least one of the voltage, SOC, and temperature of the first to N battery modules (200-1 to 200-N), thereby controlling the generator (110) and the first to N power conversion modules (120-1 to 120-N) included in the integrated power generation device (1). Here, the integrated power generation device (1) aims to perform a battery cell balancing operation of the first to N battery modules (200-1 to 200-N) by using the first to N power conversion modules (120-1 to 120-N). Accordingly, the power generation device controller (310) can control the generator (110) and the first to N power conversion modules (120-1 to 120-N) included in the integrated power generation device (1) so that the voltage or SOC of the first to N battery modules (200-1 to 200-N) become the same in order to perform a battery cell balancing operation of the first to N battery modules (200-1 to 200-N).

[0162] Accordingly, there is an effect that consistent control is possible for the power generation engine (400), the vehicle controller (500), the first to N power conversion modules (120-1 to 120-N), and the first to N battery modules (200-1 to 200-N) due to the power generation device controller (310).

[0163] [Method for controlling the first to Nth power conversion modules (120-1 to 120-N) of the power generation device controller (310)]

[0164] Next, a method for controlling the first to Nth power conversion modules (120-1 to 120-N) of the integrated power generation device (1) by the power generation device controller (310) will be described.

[0165] The power generation device controller (310) generates a charge / discharge command for each of the first to N battery modules (200-1 to 200-N) based on at least one of the voltage, SOC, and temperature of the first to N battery modules (200-1 to 200-N), thereby controlling the first to N power conversion modules (120-1 to 120-N) included in the integrated power generation device (1).

[0166] For example, if the voltage of the first to N battery modules (200-1 to 200-N) is lower than or equal to a predetermined reference voltage or the SOC is lower than or equal to a predetermined reference value, the power generation controller (310) determines that the first to N battery modules (200-1 to 200-N) require charging and may generate a charging command for each of the first to N battery modules (200-1 to 200-N). In addition, for example, if the temperature of the first to N battery modules (200-1 to 200-N) is within a predetermined range, the power generation controller (310) generates a charging / discharging command for each of the first to N battery modules (200-1 to 200-N), and if the temperature of the first to N battery modules (200-1 to 200-N) is outside the predetermined range, the power generation controller (310) does not generate a charging / discharging command for each of the first to N battery modules (200-1 to 200-N).

[0167] The method by which the power generation device controller (310) controls the first to N power conversion modules (120-1 to 120-N) of the integrated power generation device (1) in detail is as described in the power conversion module controller (121), in which the power generation device controller (310) performs the function of an external controller to control the first to N power conversion modules (120-1 to 120-N). Therefore, since the method by which the external controller controls the first to N power conversion modules (120-1 to 120-N) has been described above, a detailed description of the method by which the power generation device controller (310) controls the first to N power conversion modules (120-1 to 120-N) is omitted.

[0168] [Method for controlling a generator (110) using a generator controller (310)]

[0169] Next, a method for controlling the generator (110) of the integrated power generation device (1) by the power generation device controller (310) is described.

[0170] The power generation device controller (310) generates a torque command of the generator (110) based on at least one of the voltage, SOC, and temperature of the first to Nth battery modules (200-1 to 200-N), thereby controlling the generator (110) included in the integrated power generation device (1).

[0171] Specifically, the power generation device controller (310) determines battery status information of the first to N battery modules (200-1 to 200-N) to perform a battery cell balancing operation for the first to N battery modules (200-1 to 200-N), and based on this, determines whether a battery cell balancing operation is necessary for the first to N battery modules (200-1 to 200-N).

[0172] For example, the power generation controller (310) calculates the sum (Pc_sum) of the power required for charging of each of the first to N battery modules (200-1 to 200-N). Specifically, the power generation controller (310) can receive information about the power required for charging, which is the power required by the first to N battery modules (200-1 to 200-N), from the BMS included in each of the first to N battery modules (200-1 to 200-N), and calculate the sum (Pc_sum) of the power required for charging. Here, if Pc_sum is not 0, the power generation controller (310) operates the generator (110), and if Pc_sum is equal to 0, the generator (110) is not operated and is set to a standby mode or a stop mode to stop the operation of the generator (110).

[0173] When the generator controller (310) determines that battery cell balancing operation is required for the first to Nth battery modules (200-1 to 200-N), it generates a torque command to the generator (110). Specifically, the generator controller (310) determines the control mode of the generator (110) according to the sign of the value of Pc_sum. The torque command of the generator (110) also changes depending on the control mode of the generator (110).

[0174] The generator (110) that generates the torque command has a generation mode and a driving mode. The generation mode refers to a mode in which the generator (110) is controlled to produce power so that the first to Nth battery modules (200-1 to 200-N) are charged, and the driving mode refers to a mode in which the generator (110) is controlled to consume energy by driving a motor with power discharged from the first to Nth battery modules (200-1 to 200-N).

[0175] Next, the operation of the generator (110) by mode will be described in detail.

[0176] The generator controller (310) sets the torque command to a negative value so that the generator (110) can operate in the generation mode when Pc_sum is greater than 0. Specifically, the generator controller (310) sets the torque command so that the generator (110) operates in the generation mode because it is necessary to supply power to the first to Nth battery modules (200-1 to 200-N) for battery cell balancing operation when Pc_sum is greater than 0. Through this, the generator (110) can operate in the generation mode to charge the first to Nth battery modules (200-1 to 200-N).

[0177] The generator controller (310) sets the torque command to a positive value so that the generator (110) can operate in a driving mode when Pc_sum is less than 0. Specifically, since it is necessary to discharge the power of the first to N battery modules (200-1 to 200-N) for battery cell balancing operation when Pc_sum is less than 0, the generator controller (310) sets the torque command to a driving mode so that the generator (110) operates as a motor. Through this, the generator (110) can operate as a motor to discharge the power charged in the first to N battery modules (200-1 to 200-N) and thereby discharge the power through rotation of the motor.

[0178] That is, through this, since the power generation device controller (310) controls the battery and the first to Nth battery modules (200-1 to 200-N), battery cell balancing of the battery modules can be performed more energy-efficiently, and since the generator (110) is controlled by mode, such as the power generation mode and the driving mode, the efficiency of the control is also increased.

[0179] [Method for controlling a power generation engine (400) of a power generation device controller (310)]

[0180] A method for controlling a power generation device controller (310) to control a power generation engine (400) is described.

[0181] The power generation device controller (310) determines whether to drive the power generation engine (400) based on battery status information received from the BMS included in each of the first to N battery modules (200-1 to 200-N). For example, the power generation device controller (310) calculates the sum (Pc_sum) of the charging power required for each of the first to N battery modules (200-1 to 200-N), and if Pc_sum is greater than 0, the generator (110) is operated in power generation mode, and therefore, it is determined that the power generation engine (400) also needs to be driven.

[0182] The power generation device controller (310) transmits a driving command for the power generation engine (400) to the vehicle controller (500), and the vehicle controller (500) can drive the power generation engine (400) based on the driving command for the power generation engine (400). In addition, in order to ensure stable linked driving between the power generation engine (400) and the generator (110), the vehicle controller (500) can check the status of the power generation engine (400) in real time, generate status information of the power generation engine (400), and transmit the status information to the power generation device controller (310).

[0183] Here, the power generation device controller (310) sets the torque command to a value within the allowable torque range according to the status of the power generation engine (400). Specifically, the power generation device controller (310) receives status information of the power generation engine (400) through the vehicle controller (500). The power generation device controller (310) can control the generator (110) to a power generation mode only when the status of the power generation engine (400) is such that it can perform power generation. In addition, when generating a torque command to the generator (110), the power generation device controller (310) can generate the torque command of the generator (110) within the allowable torque range based on the specifications or current aging status of the power generation engine (400). Through this, the hardware of the power generation engine (400) is protected while the generator (110) can produce appropriate power, so the probability of failure of the power generation engine (400) and the generator (110) is reduced, and thus the maintenance and repair costs of the extended range vehicle type integrated power generation device (1) are reduced.

[0184] Next, a description will be given of a case where different types of batteries are included in the first to Nth battery modules (200-1 to 200-N). While the first to Nth battery modules (200-1 to 200-N) are typically equipped with batteries of the same type, there may also be cases where different types of batteries are installed in the first to Nth battery modules (200-1 to 200-N). In this case, there is a need to perform battery cell balancing for the different types of batteries as well.

[0185] To this end, the power generation device controller (310) controls the generator (110) and the first to N power conversion modules (120-1 to 120-N) included in the integrated power generation device (1) so that the voltages of the first to N battery modules (200-1 to 200-N) become equal to the first to N reference voltages, respectively, but at least one of the first to N reference voltages can be set to be different from the remaining reference voltages of the first to N reference voltages.

[0186] That is, since heterogeneous batteries have different chemical and electrical characteristics from other batteries, the reference voltage can be set differently from other batteries in the battery cell balancing operation so that battery cell balancing can be performed for heterogeneous batteries as well.

[0187] According to the integrated power generation device (1) and the integrated power generation system (3) for an electric vehicle with an extended range according to the present disclosure as described above, since battery cell balancing is performed using a generator (110) with phase-to-phase insulation, there is no need to install a separate battery cell balancing device, thereby reducing the manufacturing cost of the battery system and miniaturizing the volume of the battery system.

[0188] In addition, since the rectifier of the power conversion module controls power in both directions using a power semiconductor switch and simultaneously enables unit power factor control, the load torque on the shaft of the generator (110) can be maintained at a constant value. Accordingly, there is an effect of minimizing vibration caused by torque ripple of the generator (110) and reducing noise of the generator (110).

[0189] In addition, when the windings of the generator (110) are formed in multiple phases as in one embodiment of the present disclosure, the generator (110) can be driven by maximizing torque, thereby providing an effect of maximizing the charging capacity per unit volume.

[0190] In addition, the current of the generator (110) can be controlled in detail to operate the generator (110) as a motor, and through this, the driving engine coupled to the shaft of the generator (110) can be initially started, so there is an effect of being able to utilize the generator (110) as a starting motor of the engine.

[0191] The technical concepts of this disclosure should not be construed solely based on the above-described embodiments. The scope of application is diverse, and various modifications and variations are possible within the scope of those skilled in the art without departing from the spirit of the disclosure as claimed in the claims. Therefore, such improvements and modifications, as long as they are obvious to those skilled in the art, fall within the scope of protection of this disclosure.

[0192] (Explanation of symbols)

[0193] 1: Integrated power generation unit

[0194] 110: Generator

[0195] 111-1 ~ 111-N: 1st to Nth stator windings

[0196] 112: Stator

[0197] 1121: York

[0198] 1122: Tees

[0199] 113: Rotor

[0200] 1131: Core

[0201] 1132: N-pole permanent magnet

[0202] 1133: S-pole permanent magnet

[0203] 120-1 to 120-N: 1st to Nth power conversion modules

[0204] 121: Power conversion module controller

[0205] 1211: Current Command Generator

[0206] 1212: Current controller

[0207] 122-1 to 122-M: PCBs 1 to M

[0208] 200-1 to 200-N: 1st to Nth battery modules

[0209] 3: Integrated power generation system for extended-range electric vehicles

[0210] 310: Generator controller

[0211] 400: Power generation engine

[0212] 500: Vehicle Controller

Claims

1. An integrated power generation device capable of independently charging and discharging each of the first to N battery modules (wherein N is a natural number greater than 1), A generator having first to N stator windings; and It includes 1 to N power conversion modules, one side of which is connected to the 1 to N stator windings respectively, and the other side of which is connected to the 1 to N battery modules respectively; The generator has a structure in which a stator winding connected to an i-th power conversion module, which is one of the first to N power conversion modules, and a stator winding connected to a j-th power conversion module, which is another one of the first to N power conversion modules, are insulated from each other. An integrated power generation device in which each of the first to N power conversion modules independently charges and discharges each of the first to N battery modules.

2. In paragraph 1, An integrated power generation device, wherein each of the first to N stator windings is a single-phase winding electrically insulated from each other.

3. In paragraph 2, The above first to N stator windings are, An integrated power generation device, wherein the teeth of the stator are wound in a concentrated manner in multiples of three consecutive times so as to form a three-phase winding set.

4. In paragraph 2, The i-th power conversion module, which is any one of the first to N power conversion modules, An integrated power generation device including an H-bridge converter.

5. In paragraph 2, Each of the i-th and j-th power conversion modules connected to each of the i-th stator windings, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, An integrated power generation device that controls the phase currents flowing in the i and j stator windings so that the phase currents have a phase difference of (360 / N)° when in the starting motor mode for starting an engine connected to the generator using the generator.

6. In paragraph 2, Each of the i-th and j-th power conversion modules connected to each of the i-th stator windings, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, In the case of a power generation mode in which power is generated using the generator after the engine connected to the generator is started or a battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged, An integrated power generation device that controls each phase current so that the phase and magnitude of the phase current of the i-th power conversion module and the phase and magnitude of the phase current of the j-th power conversion module are independent of each other.

7. In paragraph 2, Each of the i-th and j-th power conversion modules connected to each of the i-th stator windings, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, In the case of a power generation mode in which power is generated using the generator after the engine connected to the generator is started or a battery cell balancing mode in which at least one of the first to N battery modules is charged and discharged, An integrated power generation device in which the phase currents of the i and j power conversion modules are controlled so that the phase difference between the phase currents is (360 / N)°, but the magnitudes of the phase currents are controlled independently of each other.

8. In paragraph 1, An integrated power generation device, wherein each of the first to N stator windings is a three-phase winding electrically insulated from each other.

9. In paragraph 8, The i-th power conversion module, which is any one of the first to N power conversion modules, An integrated power generation device including a three-phase PWM converter.

10. In paragraph 8, Each of the i-th and j-th power conversion modules connected to each of the i-th stator windings, which is one of the first to N stator windings, and the j-th stator winding arranged adjacent to the i-th stator winding, In the case of a starter motor mode for starting an engine connected to the generator using the generator An integrated power generation device that controls the phase currents so that the three-phase phase currents of the i-th stator winding have a phase difference of (360 / N)° from the three-phase phase currents of the j-th stator winding.

11. In paragraph 10, The above i power conversion module is, If the engine is in a power generation mode that uses the generator to generate power after starting, or a battery cell balancing mode that charges and discharges at least one of the first to N battery modules, An integrated power generation device that controls the input and output current of the i-th power conversion module based on a command from a BMS that manages the i-th battery module connected to the i-th power conversion module among the first to N battery modules.

12. In paragraph 1, The generator includes a generator case that houses a stator, a rotor, and the first to N power conversion modules therein, Each of the first to N power conversion modules is provided on the first to Mth PCBs (wherein, M is a natural number, and M≥N), An integrated power generation device in which the first to M PCBs are laminated and accommodated inside the generator case.

13. An integrated power generation system for an electric vehicle with extended range, including a power generation engine, a vehicle controller, first to Nth battery modules, and a BMS, An integrated power generation device having the characteristics of paragraph 1; and In conjunction with the vehicle controller and the BMS, a power generation device controller that controls the integrated power generation device; The above generator controller, An integrated power generation system for an electric vehicle with an extended range, which generates a torque command of the generator and a charge / discharge command for each of the first to N battery modules based on at least one of the voltage, SOC, and temperature of the first to N battery modules, thereby controlling the generator and the first to N power conversion modules included in the integrated power generation device.

14. In paragraph 13, The above generator controller, An integrated power generation system for an electric vehicle with extended range, which controls the generator and the first to N power conversion modules included in the integrated power generation device so that the voltage or SOC of the first to N battery modules becomes the same.

15. In paragraph 14, The above generator controller, Calculate the sum (Pc_sum) of the charging power required for each of the first to N battery modules, If the above Pc_sum is greater than 0, the torque command is set to a negative value so that the generator can operate in generation mode, If the above Pc_sum is less than 0, the torque command is set to a positive value so that the generator can operate in drive mode. An integrated power generation system for an electric vehicle with extended range, which sets the above torque command to a value within the allowable torque range according to the status of the power generation engine.

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