Selective response control of DC-DC converters in mild hybrid electric vehicles

Patent metadata

Field	Value
Publication number	US-10164522-B2
Application number	US-201615271808-A
Country	US
Kind code	B2
Filing date	Sep 21, 2016
Priority date	Sep 21, 2016
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

A control system for a mild hybrid vehicle is configured to detect whether a main contactor is open, the main contactor being connected between a primary battery system and a bi-directional direct current to direct current (DC-DC) converter and in response to detecting that the main contactor is open: command the DC-DC converter to operate in a boost mode to excite a motor-generator unit (MGU), after the excitation of the MGU has completed, command the DC-DC converter to operate in a buck mode, determine a previous voltage regulation feedback setpoint for the DC-DC converter, and control the DC-DC converter to maintain a voltage of the secondary battery system within a desired range by inserting a delay to a voltage control loop of the DC-DC converter such that the voltage control loop mimics a bandwidth of the MGU.

First claim

What is claimed is:

1. A method for controlling a mild hybrid vehicle, the method comprising:
detecting, by a control system of the mild hybrid vehicle, whether a main contactor is open, the main contactor being connected between a primary battery system and a bi-directional direct current to direct current (DC-DC) converter, the DC-DC converter being further connected to a secondary battery system; and
in response to detecting that the main contactor is open:
commanding, by the control system, the DC-DC converter to temporarily operate in a boost mode for a first period to excite a motor-generator unit (MGU), the MGU being coupled to a crankshaft of the engine and connected to the DC-DC converter;
after the first period and when the excitation of the MGU has completed, commanding, by the control system, the DC-DC converter to operate in a buck mode;
determining, by the control system, a previous voltage regulation feedback setpoint and a current voltage regulation feedback setpoint for the DC-DC converter; and
operating the DC-DC converter in the buck mode and maintaining a voltage of the secondary battery system within a desired range to prevent voltage undershoots and overshoots of the secondary battery system by:
controlling, by the control system, the DC-DC converter based on the previous voltage regulation feedback setpoint for a second period, wherein a duration of the second period is based on a difference between bandwidths of the DC-DC converter and the MGU, and
after the second period, controlling, by the control system, the DC-DC converter based on the current voltage regulation feedback setpoint.

2. The method of claim 1 , further comprising storing, by the control system, the current voltage regulation feedback setpoint for the DC-DC converter.

3. The method of claim 2 , wherein the current voltage regulation feedback setpoint is retrieved as the previous voltage regulation feedback setpoint during a subsequent control cycle of the DC-DC converter.

4. The method of claim 1 , wherein the second period is a predetermined period.

5. The method of claim 4 , wherein the duration of the second period is approximately 1-2 milliseconds.

6. The method of claim 1 , further comprising after the first period and in response to the excitation of the MGU completing, commanding, by the control system, the DC-DC converter to operate in an idle mode for an idle period.

7. The method of claim 6 wherein the control system commands the DC-DC converter to operate in the buck mode after the idle period.

8. The method of claim 1 , further comprising receiving, by the control system, a fault signal indicative of the open main contactor.

9. The method of claim 1 , wherein a primary voltage rating of the primary battery system is approximately 48 volts and a secondary voltage rating of the secondary battery system is approximately 12 volts.

10. The method of claim 9 , wherein the desired range for the secondary battery system is from approximately 11 volts to 13.5 volts.

11. A mild hybrid vehicle, comprising:
a primary battery system associated with a primary voltage;
a secondary battery system associated with a lesser secondary voltage;
a bi-directional direct current to direct current (DC-DC) converter connected between the primary and secondary battery systems;
an engine configured to rotatably drive a crankshaft;
a motor-generator unit (MGU) connected to the DC-DC converter and the primary battery system and coupled to the crankshaft; and
a main contactor (a) connected between (i) the primary battery system and (ii) the DC-DC converter and the MGU and (b) configured to open in response to a fault, thereby disconnecting the DC-DC converter from the primary battery system;
a control system configured to, in response to detecting that the main contactor is open:
command the DC-DC converter to temporarily operate in a boost mode for a first period to excite the MGU;
after the first period and when excitation of the MGU has completed, command the DC-DC converter to operate in a buck mode;
determine a previous voltage regulation feedback setpoint and a current voltage regulation feedback setpoint for the DC-DC converter; and
operate the DC-DC converter in the buck mode and maintain the secondary voltage of the secondary battery system within a desired range to prevent voltage undershoots and overshoots of the secondary battery system by:
controlling the DC-DC converter based on the previous voltage regulation feedback setpoint for a second period, wherein a duration of the second period is based on a difference between bandwidths of the DC-DC converter and the MGU, and
after the second period, controlling the DC-DC converter based on the current voltage regulation feedback setpoint.

12. The vehicle of claim 11 , wherein the control system is further configured to store the current voltage regulation feedback setpoint for the DC-DC converter.

13. The vehicle of claim 12 , wherein the current voltage regulation feedback setpoint is retrieved as the previous voltage regulation feedback setpoint during a subsequent control cycle of the DC-DC converter.

14. The vehicle of claim 11 , wherein the second period is a predetermined period.

15. The vehicle of claim 14 , wherein the duration of the second period is approximately 1-2 milliseconds.

16. The vehicle of claim 11 , wherein the control system is further configured to, after the first period and in response to the excitation of the MCU completing, command the DC-DC converter to operate in an idle mode for an idle period.

17. The vehicle of claim 16 wherein the commanding of the DC-DC converter to operate in the buck mode occurs after the idle period.

18. The vehicle of claim 11 , wherein the control system is further configured to receive a fault signal indicative of the open main contactor.

19. The vehicle of claim 11 , wherein a primary voltage rating of the primary battery system is approximately 48 volts and a secondary voltage rating of the secondary battery system is approximately 12 volts.

20. The vehicle of claim 19 , wherein the desired range for the secondary battery system is from approximately 11 volts to 13.5 volts.

Assignees

• Kashyap Amshumaan R
• Maruneni Sricharan
• Gross Oliver
• Fca Us Llc

Inventors

• Kashyap Amshumaan R
• Maruneni Sricharan
• Gross Oliver

Classifications

• B60L3/0023

  Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train · CPC title

• Y02T90/14

  Plug-in electric vehicles · CPC title

• B60W20/50

  Control strategies for responding to system failures, e.g. for fault diagnosis, failsafe operation or limp mode · CPC title

• B60K6/485

  Motor-assist type · CPC title

• Y10S903/906

  Motor or generator · CPC title