Patent Application
20250026208
Plug-in hybrid electric vehicles, full electric vehicles, and extended-range electric vehicles, collectively referred to herein as EVs for simplicity, are equipped with an electrified powertrain system. One or more electric traction motors of the electrified powertrain system are energized by a controlled discharge of a high-voltage traction battery pack. An energized traction motor generates output torque, which in turn is directed to one or more road wheels of the EV. The EV is thus propelled along a road surface by the electrically-driven rotation of the road wheels.
Constituent electrochemical battery cells of a depleted traction battery pack of a typical EV may be selectively recharged using an offboard plug-in charging process, with some battery packs also being rechargeable during EV operation via regenerative braking or other regenerative functions. As appreciated in the art, offboard charging requires the battery pack to be electrically connected to an alternating current (AC) or direct current (DC) Electric Vehicle Supply Equipment (EVSE) charging station via a charging cable. After communication and control circuitry of the charging station and the EV establish two-way communications in accordance with a suitable charging protocol, the charging station offloads a charging current to the depleted battery pack to thereby charge the individual cells of the battery pack to a threshold state of charge or voltage capability.
Disclosed herein is a portable charging circuit accessory, hereinafter referred to as a charging box for simplicity, and a corresponding method for performing charging operations between a charge-providing system (“donor”) and a charge-receiving system (“recipient”) using the charging box. The underlying charging architecture, circuitry, and charging strategy as described in detail herein enables high-voltage energy transfer to occur between the donor and recipient systems, e.g., full battery electric vehicles or plug-in hybrid electric vehicles (EVs), or possibly between two battery electric systems in non-EV extensions of the present teachings.
In a particular embodiment, a charging box for performing a direct current fast charging (DCFC) session of the recipient by the donor, the charging box includes a portable housing having an inlet charging port and an outlet charging port that are connectable to the donor and the recipient, respectively. The charging box also includes a high-voltage (HV) bus, first and second sets of HV disconnect devices connected to the HV bus that are configured to connect/disconnect the respective inlet and outlet charging ports to/from the HV bus, and one or more direct current-to-direct current (DC-DC) converters connected to the portable housing. The DC-DC converter(s) include a high-voltage-to-high-voltage (HV-HV) converter connected to the HV bus, and in some embodiments also include a high-voltage-to-low-voltage (HV-LV) converter connected to the HV-HV converter.
Additionally, an optional low-voltage (LV) energy storage device could be connected to the portable housing and the above-noted HV-LV converter when used, or the charging box could be connected to available 12V power, e.g., on a vehicle in such a host system. A communication processing unit (CPU) is configured to establish and maintain two-way communication between the donor and the recipient during the DCFC charging session. A system controller is configured, during the DCFC charging session, to selectively pre-charge the HV bus between the inlet charging port and the HV-HV converter if needed, to recharge the optional LV energy storage device when such a device is used, and to selectively command an offloading of a DC charging current from a battery pack of the donor, through the HV-HV converter, and to a battery pack of the recipient.
The portable housing in one or more embodiments defines a housing volume. In such an instance, the HV-HV converter, the CPU, and the system controller collectively form part of a charging circuit positioned within the housing volume.
The first and second sets of HV disconnect devices may include a first set of HV contactors and a second set of HV contactors connected to the inlet charging port and the outlet charging port by a corresponding fuse.
The optional LV energy storage device may include a 12-15 volt battery pack in one or more embodiments, or a 12-15 volt ultracapacitor or supercapacitor.
The HV-HV converter may be configured as a buck-boost converter.
An aspect of the disclosure includes a human-machine interface (HMI) connected to the portable housing. The HMI is configured to receive user inputs to the system controller during the DCFC session, and to display information pertaining to the DCFC session.
The charging box may also include a thermal management system operable for regulating a temperature of the multiple DC-DC converters.
The aforementioned CPU includes corresponding communication stacks for the donor and the recipient, and an application layer connected to the communication stacks to facilitate the two-way communication between the donor and the recipient.
The system controller for its part may quantify the DCFC charging session as a quantified session upon completion thereof, to generate a summary of charges for the DCFC charging session based on the quantified session, and to communicate the summary of charges to a user of the recipient. The system controller may also optionally perform an adaptive self-learning algorithm to analyze charging behavior of a group of recipients from prior DCFC charging sessions, and to adjust performance of the charging box over time based on the charging behavior.
The recipient and the donor may each be configured as a battery electric vehicle or a plug-in hybrid electric vehicle, in which case the above-noted DCFC charging session is a vehicle-to-vehicle charging session.
Also disclosed herein is a vehicle-to-vehicle (V2V) charging box for performing a DCFC session of a charge-receiving vehicle (“recipient”) by a charge-providing vehicle (“donor”). The V2V charging box may include a portable housing that defines a housing volume and includes inlet and outlet charging ports that are connectable to the donor and the recipient, respectively. The V2V charging box also includes the HV bus, first and second sets of HV contactors connected to the HV bus, and an HV-HV converter connected to the HV bus. The HV-HV converter is configured to output charging power of at least about 50 kilowatts (kW).
The V2V charging box in this embodiment also includes a thermal management system operable for regulating a temperature of the HV-HV converter, as well as a communication processing unit (CPU) configured to establish and maintain two-way communication between the donor and the recipient during the DCFC charging session. The CPU includes corresponding communication stacks for the donor and the recipient, and an application layer connected to the communication stacks to facilitate the two-way communication between the donor and the recipient.
As part of this embodiment, a system controller is configured, during the DCFC charging session, to selectively pre-charge the HV bus between the inlet charging port and the HV-HV converter, to recharge the optional LV energy storage device when used, and to selectively command an offloading of a DC charging current from a battery pack of the donor, through the HV-HV converter, and to a battery pack of the recipient. The high-voltage bus, the first and second sets of HV contactors, the DC-DC converter(s), the CPU, and the system controller are positioned within the housing volume.
A V2V charging method is also disclosed herein, an embodiment of which includes detecting a predetermined electrical connection of the donor and recipient to a V2V charging box via a system controller thereof. The predetermined electrical connection includes a connection of the donor and the recipient to an inlet charging port and an outlet port of a portable housing of the V2V charging box, respectively. The method also includes establishing two-way communication between the donor and the recipient using a communication processing unit (CPU) of the V2V charging box, with the CPU being connected to an LV energy storage device within the V2V charging box. The CPU includes corresponding communication stacks for the donor and the recipient and an application layer connected to the communication stacks to facilitate the two-way communication.
During a V2V charging session, the method includes commanding, via a system controller of the V2V charging box, an HV-LV converter of the V2V charging box to pre-charge an HV bus between the inlet charging port and an HV-HV converter of the V2V charging box, selectively recharging the LV energy storage device via the HV-LV converter, and offloading of a DC charging current from a battery pack of the donor, across a first set of contactors of the V2V charging box, through the HV-HV converter, across a second set of contactors of the V2V charging box, and to a battery pack of the recipient to thereby perform the V2V charging session.
The above features and advantages, and other features and attendant advantages of this disclosure, will be readily apparent from the following detailed description of illustrative examples and modes for carrying out the present disclosure when taken in connection with the accompanying drawings and the appended claims. Moreover, this disclosure expressly includes combinations and sub-combinations of the elements and features presented above and below.
The present disclosure may be modified or embodied in alternative forms, with representative embodiments shown in the drawings and described in detail below. Inventive aspects of the present disclosure are not limited to the disclosed embodiments. Rather, the present disclosure is intended to cover alternatives falling within the scope of the disclosure as defined by the appended claims.
Referring to the drawings, wherein like reference numbers refer to like features throughout the several views,
The donor 12D and the recipient 12R as contemplated herein include a body 13D, 13R and a corresponding electric powertrain system 50D and 50R. In a typical configuration, the donor 12D includes a charging port 16 that is connected to a high-voltage (HV) electrochemical traction battery pack (BHV) 18 via a set of onboard DCFC contactors 20. The battery pack 18 in turn is connected to a power inverter module (PIM) 22. In a discharging mode of the battery pack 18, the battery pack 18 delivers a DC voltage (VDC) to a DC-side of the PIM 22. The PIM 22, using ON/OFF conductive state control of multiple solid-state semiconductor switches (not shown) such as IGBTs, MOSFETs, thyristors, or the like, is driven by pulse-width modulation or another suitable switching control technique.
Switching control of the PIM 22 ultimately converts the DC input voltage from the battery pack 18 into an alternating current voltage (VAC) suitable for energizing phase windings of an electric traction motor (ME) 24, thus causing machine rotation. Output torque (arrow To) from the electric traction motor 24 is then delivered to one or more road wheels 26 of the donor 12D. The recipient 12R shown in
Referring briefly to
As appreciated in the art and noted above, the donor 12D and the recipient 12R are respectively equipped with the above-noted traction battery packs 18 and 118. Additionally, the donor 12D would include an onboard vehicle controller 32 (CD) having one or more processors (P) 36, memory (M) 38, and an instruction set 100S embodying the present method 100 of
To perform the functions of the present method 100, e.g., by executing one or more algorithms and automated and/or manual process steps as set forth below, such functions could be embodied computer-readable instructions, i.e., the instruction set 100S, from a tangible, non-transitory computer-readable storage medium portion of the associated memory 38 and 138. For instance, the memory 38 and 138 could include magnetic or optical media, CD-ROM, and/or solid-state/semiconductor memory (e.g., various types of RAM or ROM). The term “vehicle controller” and related terms such as control module, control unit, processor, and similar terms may refer to one or various combinations of Application Specific Integrated Circuit(s) (ASIC), Field-Programmable Gate Array (FPGA), electronic circuit(s), central processing unit(s), e.g., microprocessor(s) and associated non-transitory memory component(s) in the form of memory and storage devices (read only, programmable read only, random access, hard drive, etc.). Non-transitory components of the memory 38 and 138 used herein are capable of storing machine-readable instructions in the form of one or more software or firmware programs or routines, combinational logic circuit(s), input/output circuit(s) and devices, signal conditioning and buffer circuitry and other components that can be accessed by one or more processors 34 and 134 to provide a described functionality.
Still referring to
Referring now to
Multi-pin charging plugs 30C disposed the charging cables 30 are connected to a corresponding one of the charging ports 16, 116 located on the donor 12D and recipient 12R, respectively (see
V2V CHARGING BOX CONTENTS: the V2V charging box 14 illustrated in
The housing 40 defines a housing volume 400. One or more direct current-to-direct current (DC-DC) converters are arranged in the housing volume 400 and connected to the housing 40 for secure transport and operation. In the illustrated embodiment of
The V2V charging box 14 illustrated in
To that end, the CPU 55 may be equipped, during the V2V charging session 10, to coordinate with the above-noted processors 36 and 136 of the respective donor 12D and recipient 12R. Communication is facilitated via one or more communication modules connected to/usable with the application layer 60, e.g., a BLE/WiFi/LTE software module 60A, ISO-20 communications software module 60B, DIN communications software module 60C, and ISO-3 communications software module 60D as shown in the non-limiting example construction of
Using the comms stacks 58 and 158, the application layer 60, and the associated software modules 60A, 60B, and 60c, the CPU 55 is able to command the HV-LV converter 46 to pre-charge an HV bus 56 of the V2V charging box 14 to a level equal to that of an HV bus located on the donor 12D, and in selectively recharging the LV energy storage device 48 via the HV-LV converter 46 as needed. Additionally, the CPU 55 in close coordination with the processors 36 and 136 of
Still referring to
Other components of the V2V charging box 14 may include a human-machine interface (HMI) 70 connected to the portable housing 40 and configured to facilitate interaction-machine interactions during the course of the V2V session 10 of
Additionally, a thermal management system (TMS) 72 could be incorporated into the V2V charging box 14 or connected thereto to regulate the temperature of high-voltage and other components contained therein, in particular the HV-HV converter 44 and the optional HV-LV converter 46. By way of example and not of limitation, the thermal management system 72 could include a heat sink with conductive and/or forced convective devices, e.g., cooling plates, fans, etc., fluidic means such as coolant loops/pumps, cooling blankets, and the like. In some implementations, the thermal management system 72 could include optional phase change materials to optimize mass, transient heat rejection capability, etc.
In general, the method 100 described below includes detecting a predetermined electrical connection of the donor 12D and recipient 12R to the charging box 14 via the system controller 61 thereof, with the predetermined electrical connection including a connection of the donor 12D and the recipient 12R to the respective inlet charging port 42 and the outlet port 142 of the portable housing 40 shown in
Referring to
Referring first to
At block B104, the donor 12D arrives on site and is parked in proximity to the recipient 12R. The donor 12D in this instance could pull up in front of or next to the recipient 12R such that the charging ports 16 and 116 are readily accessible to one other. The method 100 thereafter proceeds to block B106.
Block B106 of
At block B108, which is analogous to block B106, another charging cable 30 is connected between the outlet charging port 142 of the V2V charging box 14 and the charging port 116 of the recipient 12R. Thus, upon completion of block B108 the donor 12D is electrically connected to the recipient 12R via the intervening V2V charging box 14. The method 100 thereafter proceeds to block B110.
Block B110 of
Referring now to
Block B113 entails determining whether an electronic handshake signal, e.g., a Transport Layer Security (TLS) handshake, has been received from the recipient 12R by the donor 12D. As appreciated in the art, such a handshake signal is often used to establish an encrypted two-way communication session between a charge provider and a charge recipient during EV charging. This is extended to the present DCFC/V2V charging scenario. The method 100 proceeds to block B114 when the handshake signal has been received by the donor 12D, and to block B106 of
At block B114 of
Block B115 entails determining, via the system controller 61 of the V2V charging box 14, whether the DCFC contactors 20 (
Block B116 is performed when the DCFC contactors 20 aboard the donor 12D and the first set of disconnect devices 62 of the V2V charging box 14 are closed. In this case, the system controller 61 transitions the HV-LV converter 46 into a voltage-reducing “buck” mode to maintain the LV energy storage device 48 at a calibrated low voltage level, e.g., nominally 12-15V as noted above. The method 100 proceeds to block B118 once the buck mode has been enacted.
At block B117, which is analogous to block B113, the system controller 61 of the V2V charging box 14 verifies that the handshake signal has been received from the donor 12D. In this case, the V2V charging box 14 acts for resident logic of the recipient 12R. The method 100 proceeds to block B118 when the handshake signal has been received, and to block B106 of
Block B118 of
At block B120, the DCFC contactors 120 of the recipient 12R are verified as having been closed in a process step that is analogous to that performed in block B115. In response, the method 100 proceeds to block B122. The method 100 otherwise repeats block B117.
At block B122, the energy transfer process initiates in response to the forgoing process steps. The system controller 61, working in concert with the controllers 32 and 132 of
Blocks B124 and B126 of
Referring now to
At block B127, the system controller 61 of
Block B128, which is reached when the SOC of the donor 12D or recipient 12R reaches the predetermined SOC limit of block B127, includes terminating the DCFC charging event from the standpoint of the recipient 12R. This could entail transmitting the requisite signals from the comms stack 158 to the V2V charging box 14 indicating the recipient 12R no longer requires charging. As part of block B128, the system controller 61 may command the disconnect device 162 to open, thus breaking the high-voltage connection between the V2V charging box 14 and the recipient 12R. Aboard the recipient 12R, the DCFC contactors 120 of
At block B129, the system controller 61 of the V2V charging box 14 next determines whether a user has requested termination of the V2V session 10. For example, the owner/operator of the donor 12D or recipient 12R could communicate a desire to stop the V2V charging session 10 via wireless or HMI-based communication with the CPU 55, e.g., via the HMI 70 of
Block B130, analogous to block B128, entails terminating the V2V session 10 from the standpoint of the donor 12D. This process is performed in close coordination with the above-described process of block B128. The method 100 thereafter proceeds to block B136.
At block B132 of
Block B134 entails discontinuing the above-described handshake signal and terminating the V2V charging session 10. The method 100 thereafter proceeds to optional block B136.
Block B136 of
Similar technology could likewise facilitate communication with other vehicles/devices. To that end, the V2V charging box 14 shown in
Optionally, the V2V charging box 14 or the above-noted backend server could be configured to create unique user profiles of charging parameters for a given population of recipients 12R, such as similarly equipped EVs. The V2V charging box 14 could use adaptive self-learning algorithm or other techniques to analyze the collective charging behavior of such a group of recipients 12R from prior V2V sessions 10, which would enable the V2V charging box 14 to adjust the performance of the V2V charging box 14 and improve the charging experience for future usages. The method 100 is complete upon completion of the optional quantification/monetization process of block B134. The LV energy storage device then goes into a low-power standby mode until the V2V charging box 14 is again needed for a subsequent V2V charging session.
The mobile DCFC-related hardware and software solutions described above thus provide an electrical architecture that enables energy transfer to occur between two EVs or other battery electric systems equipped having a high-voltage rechargeable energy storage system, exemplified herein as the traction battery packs 18 and 118 of
The present disclosure is susceptible of embodiment in many different forms. Representative examples of the disclosure are shown in the drawings and described herein in detail as non-limiting examples of the disclosed principles. To that end, elements and limitations described in the Abstract, Introduction, Summary, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference, or otherwise.
For purposes of the present description, unless specifically disclaimed, use of the singular includes the plural and vice versa, the terms “and” and “or” shall be both conjunctive and disjunctive, “any” and “all” shall both mean “any and all”, and the words “including”, “containing”, “comprising”, “having”, and the like shall mean “including without limitation”. Moreover, words of approximation such as “about”, “almost”, “substantially”, “generally”, “approximately”, etc., may be used herein in the sense of “at, near, or nearly at”, or “within 0-5% of”, or “within acceptable manufacturing tolerances”, or logical combinations thereof.
The detailed description and the drawings or figures are supportive and descriptive of the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings defined in the appended claims. Moreover, this disclosure expressly includes combinations and sub-combinations of the elements and features presented above and below.
