Patent Application
20240042881
The present disclosure relates to charging by electrical vehicles.
When performing a vehicle-to-load or vehicle-to-other (V2X) charging event, such as without limitation a vehicle-to-vehicle (V2V) charging event, isolation of a high voltage cable between a donor vehicle and a V2X charging device should be verified (sometimes referred to as a cable check) and the V2X charging device's direct current (DC)-DC converter's input should be pre-charged prior to closing the donor vehicle's disconnect device. However, currently-known V2X charging devices may have no high voltage energy source prior to closing of the donor vehicle's disconnect device.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Various disclosed embodiments include illustrative DC bus charge modules, V2X charging devices, and methods for pre-charging a V2X charging device.
In an illustrative embodiment, a DC bus charge module includes a DC boost converter configured to: apply an output DC voltage from the DC boost converter and having a first voltage level to a DC bus cable with the DC bus cable disconnected from a first DC voltage source; and charge an electrical charge storage device that is electrically connectable to the DC bus cable with an output DC voltage from the DC boost converter and having a second voltage level that is different from the first voltage level with the DC bus cable disconnected from the first DC voltage source.
In another illustrative embodiment, a V2X charging device includes a high voltage direct current (DC)-DC converter, an electrical charge storage device electrically connectable to the input of the DC-DC converter, and a DC bus charge module including a DC boost converter. The DC boost converter is configured to: apply an output DC voltage from the DC boost converter and having a first voltage level to a DC bus cable electrically connectable to an input of the DC-DC converter with the DC bus cable disconnected from a first DC voltage source; and charge the electrical charge storage device with an output DC voltage from the DC boost converter and having a second voltage level that is different from the first voltage level with the DC bus cable disconnected from the first DC voltage source.
In another illustrative embodiment, a method includes: applying an output direct current (DC) voltage from a DC boost converter and having a first voltage level to a DC bus cable with the DC bus cable disconnected from a first DC voltage source; and charging an electrical charge storage device that is electrically connectable to the DC bus cable with an output DC voltage from the DC boost converter and having a second voltage level that is different from the first voltage level with the DC bus cable disconnected from the first DC voltage source.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
Illustrative embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
Like reference symbols in the various drawings generally indicate like elements.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
Various disclosed embodiments include illustrative DC bus charge modules, V2X charging devices, and methods for pre-charging a V2X charging device.
Given by way of overview and referring to
Still by way of overview, it will be appreciated that, in various embodiments, insulation of the DC bus cable 14 can be verified without the DC bus cable 14 being electrically connected to the first DC voltage source BT1 (such as a high voltage DC electrical battery of a donor vehicle 20) and that, in various embodiments, the DC-DC converter 12 can be pre-charged without the DC bus cable 14 being electrically connected to the first DC voltage source BT1.
It will be appreciated that V2X charging sessions associated with various disclosed embodiments entail use of the V2X charging device 10 that is interposed between the donor vehicle 20 and a recipient load 22. As shown in
In various embodiments the DC bus cable 14 and the cable 24 include any suitable cables configured to distribute high voltage DC electrical power (such as on the order of around 450V or so). Because the DC bus cable 14 is configured to distribute high voltage DC electrical power from the donor vehicle 20, in various embodiments the DC bus cable 14 includes a suitable connector configured to electrically connect the DC bus cable 14 to the V2X charging device 10. In various embodiments, such a suitable connector may include, without limitation, a combined charging system (CCS) Type 1 and/or Type 2 coupler, a CHAdeMo coupler, a GB/T coupler, a Tesla connector, and/or the like. In various embodiments, the cable 24 also includes a suitable connector configured to electrically connect the cable 24 to the V2X charging device 10. In various embodiments, such a suitable connector also may include, without limitation, a combined charging system (CCS) Type 1 and/or Type 2 coupler, a CHAdeMo coupler, a GB/T coupler, a Tesla connector, and/or the like.
In various embodiments the V2X charging device 10 includes switches S4a and S4b that are interposed between input terminals of the DC-DC converter 12 and the DC bus cable 14 and switches S5a and S5b that are interposed between output terminals of the DC-DC converter 12 and the cable 24. The DC-DC converter 12 adjusts DC voltage level of DC electrical power supplied by the donor vehicle 20 as desired for charging the recipient load 22. That is, the DC-DC converter 12 can increase and/or decrease the DC voltage of the electrical energy supplied from the donor vehicle 20 to match operating voltage of the recipient load 22.
It will be appreciated that, in various embodiments, the recipient load 22 can communicate charge limits, voltage limits, and/or charge status so that the V2X charging device 10 can take desired actions to help contribute to effecting safe energy transfer, such as, for example, asking the donor vehicle 20 to close contractors (such as, for example, switches S3a and S3b) for energy transfer, looking for faults on the donor vehicle 20 or the recipient load 22, or the like.
While the V2X charging device 10 may be referred to as “V2V Equipment” and the recipient load 22 may be referred to as a “Recipient Vehicle,” it will be appreciated that the recipient load 22 is not limited to a vehicle but may be any load whatsoever as desired, a battery or a bank of batteries, any suitable energy storage device such as a capacitor or a bank of capacitors, an energy storage system with batteries, and/or an energy storage system with solar cells with associated electronics, or the like.
In various embodiments and referring additionally to the sequence diagram of
In various embodiments, upon commencement of a V2X charging event or session, the V2X charging device 10 waits for a response from the donor vehicle 20 and the donor vehicle 20 waits for user input via a human-machine interface (HMI) (not shown for purposes of clarity)—such as a control and display panel of the V2X charging device 10, an infotainment system of the donor vehicle 20, a light on a charge port (not shown for purposes of clarity), or the like—to set up the V2X charging session.
In various embodiments a user may input any desired parameters of the charge (such as, for example, end range, time, state of charge (SOC), amount of energy (in KW-Hrs), or the like). In some embodiments the donor vehicle 20 may set an end range for the donor vehicle 20 as a default parameter for energy transfer. In some such embodiments, the end range may be set to a range needed to complete a route (if a route has been entered), distance to nearest DC fast charging station, or to a default value to ensure the user has enough range based upon user settings.
In various embodiments, charge parameters may be based, at least in part, on one or more parameters of one or more planned additional recipient loads 22. For example, if the donor vehicle 20 is configured to transfer energy to multiple recipient loads 22 (for example, if the donor vehicle 20 is a rescue vehicle configured to provide energy to multiple recipient loads 22 in a single trip), then the donor vehicle 20 may set an end range for the donor vehicle 20 and an amount of energy allotted to the additional planned recipient loads 22 as a default parameter for energy transfer, where the amount of energy allotted to the additional planned recipient loads 22 may be communicated to the donor vehicle 20 from the additional planned recipient loads 22, such as, for example, via cloud-based communication or the like.
In various embodiments a user may also be given an option to set a desired end state of charge (SOC) for the recipient load 22 if the V2X charging device 10 is transferring power to an energy storage system.
Responsive to a user entering a selection and beginning a charging session, the donor vehicle 20 sends the V2X charging device 10 an end SOC for the recipient load 22 and monitors selections of the donor vehicle 20.
After the V2X charging session is initialized, to help contribute to providing safety the V2X charging device 10 begins an isolation check of the high voltage bus cable 14 and pre-charges the high voltage bus cable 14 as will be explained further below.
It will be appreciated that various embodiments described herein can help permit initializing a V2X charging event and/or session. It will also be appreciated that various embodiments described herein can help permit, for example and without limitation, charging of the recipient load 22 such as without limitation a vehicle by the donor vehicle 20, transferring power from the donor vehicle 20 to a home or other structure or the like through DC charge pins, or for support vehicles to rescue stranded vehicles without adding any extra communication hardware to the donor vehicle.
Now that an overview has been given, details of various embodiments will be set forth by way of non-limiting embodiments that are given by way of illustration only and not of limitation. To that end, in various embodiments, illustrative systems and methods for performing cable check and performing pre-charge of a vehicle-to-load power converter in a vehicle-to-load charging session are provided.
As discussed above, when performing a V2X charging event, in various embodiments insulation of the DC bus cable 14 is verified and the input of the DC-DC converter 12 of the V2X charging device 10 is pre-charged prior to closing the donor vehicle's disconnect device(s) (that is, the switches S3a and S3b of the donor vehicle 20).
As shown in
In various embodiments the V2X charging device 10 includes the high voltage direct current DC-DC converter 12. The DC bus cable 14 is electrically connectable to the input 16 of the DC-DC converter 12. The electrical charge storage device C1 is electrically connectable to the input 16 of the DC-DC converter 12. The DC bus charge module 18 includes the DC boost converter 26 (
In various embodiments the DC-DC converter 12 converts input DC voltage from the DC voltage source BT1 of the donor vehicle to a requested output DC voltage that is provided to the recipient load 22. The DC-DC converter 12 is any suitable DC-DC converter as desired for a particular application. An explanation of details of construction and operation of the DC-DC converter 12 is not necessary for a person of skill in the art to understand disclosed subject matter.
In various embodiments, the DC-DC converter 12 includes the electrical charge storage device C1, and the electrical charge storage device C1 is electrically connected within the DC-DC converter 12 across terminals of the input 16 of the DC-DC converter 12. In some embodiments, the electrical charge storage device C1 may be provided separately from the DC-DC converter 12. In such embodiments, the electrical charge storage device C1 is electrically connected across the terminals of the input 16 of the DC-DC converter 12 between the switches S4a and S4b and the terminals of the input 16 of the DC-DC converter 12.
Regardless of location of the electrical charge storage device C1, as discussed herein, the electrical charge storage device C1 is charged by the DC bus charge module 18 to the DC voltage of the DC voltage source BT1 before the DC voltage source BT1 is electrically connected to the DC-DC converter 12. Thus, with the electrical charge storage device C1 charged to the DC voltage of the DC voltage source BT1, the input 16 of the DC-DC converter 12 is already at the DC voltage level of the DC voltage source BT1 when the DC voltage source BT1 is electrically connected to the V2X charging device 10. The electrical charge storage device C1 is any suitable electric charge storage device as desired, such as a capacitor or the like.
In various embodiments the DC boost converter 26 is configured to receive an input DC voltage from any suitable DC voltage source such as, without limitation, an auxiliary low voltage source, a DC power supply (such as those that convert alternating current (AC) electrical power, light, heat, or the like, to DC electrical power), an electrical battery (rechargeable or single use) or electrical batteries (rechargeable or single use), an electrical or electronic device that can supply DC electrical power, or the like. The input DC voltage has a voltage level that is less than the voltage levels of the output DC voltages of the DC boost converter (that is, the first voltage level and the second voltage level). The input DC voltage may have any suitable voltage level whatsoever as desired for a particular application. For example, in some embodiments the input DC voltage may be 12V. In some other embodiments, the input DC voltage may be 4V or, in some cases, 3.65V. However, it is emphasized that the input DC voltage may have any suitable voltage level whatsoever as desired for a particular application.
The DC boost converter 26 is configured to convert the input DC voltage to the output DC voltage (which has voltage levels greater than the input DC voltage). In various embodiments, the DC boost converter 26 converts the input DC voltage to an output DC voltage with a voltage level of around 500V to be applied to the DC bus cable 14 (before the switches s4a and s4b) to verify the insulation of the DC bus cable 14 (that is, for performing the isolation check). However, any output DC voltage level may be used that is suitable for verifying the insulation of the DC bus cable 14. In various embodiments, the DC boost converter 26 converts the input DC voltage to an output DC voltage with a voltage level of around 450V to charge the electrical charge storage device C1 to the DC voltage of the DC voltage source BT1. However, any output DC voltage level may be used that corresponds to the DC voltage of the DC voltage source BT1.
It will be appreciated that the DC boost converter 26 may be any suitable boost converter as desired. As shown in
In an on-state, a switch 27 (such as a field-effect transistor (FET)) is closed, current through a primary winding 29 of a transformer 28 increases, and magnetic flux in the transformer 28 increases, thereby storing energy in the transformer 28, The voltage induced in a secondary winding 31 is negative, so a diode 33 is reverse-biased (that is, blocked). An output capacitor Caux out supplies energy to the output load.
In an off-state, the switch 27 is open, current through the primary winding 29 drops, and magnetic flux drops. The secondary voltage is positive, thereby forward-biasing the diode 33 and allowing current to flow from the transformer 28. The energy from the core of the transformer 28 recharges the capacitor Caux out and the capacitor Caux out supplies the output DC voltage to the DC bus cable 14 for the isolation check or to the capacitor C1 for charging the capacitor C1.
In various embodiments the DC boost converter 26 could be approximately 5 W or less (depending upon size of the V2X bus capacitance). Thus, various embodiments can use a small, isolated auxiliary converter—as opposed to the primary power processing converter (that is, the DC-DC converter 12)—to perform cable check and pre-charge functions.
In various embodiments the DC boost converter 26 provides an inrush current limiting function that limits inrush current (or a switch-on surge) when the transformer 28 is first energized. An anode 30 of a Zener diode 32 is electrically connected to a first end of the primary winding 29 of the transformer 28. A cathode 34 of the Zener diode 32 is electrically connected to a cathode 36 of a diode 38. An anode 40 of the diode 38 is electrically coupled to a second end of the primary winding 29. In instances in which a Zener voltage is reached, the Zener diode 32 conducts in reverse bias. Conducting by the Zener diode 32 in reverse bias establishes a conductive loop with the diode 38 and the primary winding 33, thereby clamping the voltage spike due to leakage inductance of the transformer 28 and limiting voltage stress to the switch 27. In some such embodiments the DC bus charge module 18 is configured to implement an inrush current limit of less than 2 A or so while providing fast voltage ramp-up capability, thereby helping to reduce V2X charging session initialization time.
In various embodiments the DC bus charge module 18 includes a voltage sensor 42 configured to sense the output DC voltage. The voltage sensor 42 is electrically coupled across the capacitor Caux out to sense the output DC voltage. The voltage sensor 42 generates and outputs a signal 44 that is indicative of voltage level of sensed output DC voltage. The voltage sensor 42 can be any suitable voltage sensor as desired for a particular application, such as a resistive voltage sensor that incorporates a voltage divider or a bridge circuit.
In various embodiments the DC bus charge module 18 includes a controller 46 configured to control the DC boost converter 26 responsive to the voltage sensor 42. In such embodiments the signal 44 is provided by the voltage sensor 42 to the controller 46. In various embodiments the controller 46 includes a processor 48 and computer-readable media 50 configured to store computer-executable instructions configured to cause the processor 48 to perform various functions to control the DC boost converter 26. It will be appreciated that providing the signal 44 from the voltage sensor 42 to the controller 46 implements closed loop control—which can help permit reaching a desired pre-charge voltage quickly and accurately.
In various embodiments the processor 48 may include a computer processing unit (CPU), a general purpose processor, a digital signal processor, a field programmable gate array, or the like, and/or any combination thereof. Processors are well known and further description of their construction and operation are not necessary for an understanding by a person of skill in the art of disclosed subject matter.
In various embodiments the computer-readable media 50 may include any suitable computer memory configured to store computer-executable instructions configured to cause the processor 48 to perform functions described herein. Given by way of non-limiting examples, the computer-readable media 50 may include any suitable volatile memory elements, such as without limitation random access memory (RAM), such as dynamic RAM (DRAM), static RAM (SRAM), static-dynamic RAM (SDRAM), and the like, nonvolatile memory elements such as without limitation read-only-memory (ROM), hard drive, tape, compact-disc ROM (CDROM), and the like, and combinations thereof. Moreover, the computer-readable media 50 may incorporate electronic, magnetic, optical, and/or other types of storage media as desired.
For example, in various embodiments the instructions are configured to cause the processor 48 to verify the insulation of the DC bus cable 14 with the output DC voltage having the first voltage level. That is, in such embodiments the instructions are configured to cause the processor 48 to cause the DC boost converter 26 to convert the input DC voltage to the output DC voltage that has the first voltage level as described above. In such embodiments the instructions are further configured to cause the processor 48 to cause the DC boost converter 26 to stop converting the input DC voltage to the output DC voltage that has the first voltage level responsive to the insulation of the DC bus cable being verified. For example, if the signal 44 remains indicative of the first voltage level for a predetermined amount of time, then this sensed voltage indicates that the insulation of the DC bus cable 14 is intact and has not broken down (such as via dielectric breakdown). Thus, the processor 48 can command the DC boost converter 26 to stop converting the input DC voltage to the output DC voltage. In various embodiments, additional circuitry (not shown) may be used to verify integrity of the isolation between cables and the ground reference or chassis.
As another example, in various embodiments the instructions are further configured to cause the processor 48 to cause the DC boost converter 26 to charge the electrical charge storage device C1 to the second voltage level with the output DC voltage. That is, in such embodiments the instructions are configured to cause the processor 48 to cause the DC boost converter 26 to convert the input DC voltage to the output DC voltage that has the second voltage level as described above. In such embodiments the instructions are further configured to cause the processor 48 to cause the DC boost converter 26 to stop converting the input DC voltage to the output DC voltage responsive to the electrical charge storage device C1 being charged to the second voltage level. For example, if the signal 44 remains indicative of the second voltage level for a predetermined amount of time, then this sensed voltage indicates that the electrical charge storage device C1 is charged to the second voltage level. Thus, the processor 48 can command the DC boost converter 26 to stop converting the input DC voltage to the output DC voltage.
Various embodiments operate as follows.
A connector 52 of the DC bus cable 14 (as described above) is plugged into a receptacle 54 of the donor vehicle that is electrically connectable to the DC voltage source BT1. A connector 56 of the DC bus cable 14 (as described above) is plugged into a receptacle 58 of the V2X charging device 10. A connector 60 of the cable 24 is plugged into a receptacle 62 of the recipient load 22. A connector 64 of the cable 24 is plugged into a receptacle 66 of the V2X charging device 10.
At the start of a V2X charging session, the donor vehicle 20 will pre-charge a capacitor Cveh to a voltage level of the DC voltage source BT1 (that is, the second voltage level) by closing switches S1 and S2b. After Cveh is fully charged, the donor vehicle 20 also closes a main contactor switch S2a.
The bus charge module 20 applies the output DC voltage at the first voltage level (such as around 500V or so) to the DC bus cable 14 to verify its insulation. Once the cable check is passed, cable voltage is reduced to zero and switches S4a and S4b are closed.
The donor vehicle 20 sends the V2X charging device 10 its battery voltage amplitude (that is, voltage level of the DC voltage source BT1) via a suitable message. The DC bus charge module 18 charges the electrical charge storage device C1 to the target battery voltage (that is, the voltage level of the DC voltage source BT1). Once the target battery voltage is reached, the donor vehicle 20 closes the switches S3a and S3b. The bus charge module 18 is then disabled.
After the donor side connection is fully established, the main power converter (that is, the DC-DC converter 12) can be used to perform the same functions for the recipient load 22. That is, the DC-DC converter 12 can then turn on and start cable check and voltage match to the recipient load 22. That is, the V2X charging device 10 can act as a typical DC fast charging station and perform cable checks and voltage match on its output to the recipient load 22.
Once this process is complete power transfer can commence. It will be appreciated that the recipient load 22 can communicate charge limits, voltage limits, and charge status so that the V2X charging device 10 can take desired actions to help contribute to effecting safe energy transfer, such as asking the donor vehicle 20 to close switches for energy transfer, looking for faults on the donor vehicle 20 or the recipient load 22, or the like.
In various embodiments and referring additionally to
In various embodiments and referring additionally to
In various embodiments and referring additionally to
In various embodiments and referring additionally to
In some instances, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Those skilled in the art will recognize that such terms (for example “configured to”) generally encompass active-state components and/or inactive-state components and/or standby-state components, unless context requires otherwise.
While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (for example, bodies of the appended claims) are generally intended as “open” terms (for example, the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (for example, “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (for example, the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”
The foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, flowcharts, and/or examples. Insofar as such block diagrams, flowcharts, and/or examples contain one or more functions and/or operations, it will be understood by those within the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware.
With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.
While the disclosed subject matter has been described in terms of illustrative embodiments, it will be understood by those skilled in the art that various modifications can be made thereto without departing from the scope of the claimed subject matter as set forth in the claims.
The present disclosure claims the benefit of priority of co-pending International Application No. PCT/US21/51113, filed on Sep. 20, 2021, and entitled “SYSTEMS AND METHODS FOR PRE-CHARGING VEHICLE-TO-LOAD CHARGER,” which claims priority to U.S. Provisional Patent Application No. 63/080,026, filed on Sep. 18, 2020, and entitled “SYSTEMS AND METHODS FOR PERFORMING VEHICLE-TO-LOAD CHARGING,” the contents of which are incorporated in full by reference herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US21/51113 | 9/20/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63080026 | Sep 2020 | US |
