Bidirectional integrated charger for a vehicle battery

Patent metadata

Field	Value
Publication number	US-10946756-B2
Application number	US-201715812498-A
Country	US
Kind code	B2
Filing date	Nov 14, 2017
Priority date	Nov 14, 2017
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

A vehicle includes an integrated power distribution module. The integrated power distribution module includes a hybrid transformer coupled to a charger stage, a traction battery, and an auxiliary battery. The hybrid transformer includes first and second primary windings coupled in series and connected to the charger stage. The primary windings have a corresponding first secondary winding coupling the traction battery via associated inverters. The primary windings further have corresponding second secondary windings that are coupled in series with opposing voltage polarities and coupled to the auxiliary battery via an associated inverter.

First claim

What is claimed is:

1. A vehicle comprising:
a hybrid transformer including first and second primary windings directly coupled in series with opposite polarity and selectively electrically coupled to an external source, the first primary winding being configured to electro-magnetically couple to a first and second secondary winding, and the second primary winding being configured to electro-magnetically couple to a third and fourth secondary winding, the first and fourth secondary windings being selectively electrically coupled to a traction battery, and the second and third secondary windings being directly coupled in series with same polarity to define a port that is selectively electrically coupled to an auxiliary battery.

2. The vehicle of claim 1 wherein the first and second primary windings are coupled to the external source by at least one power inverter that is configured to bidirectionally convert power between direct current (DC) and alternating current (AC).

3. The vehicle of claim 2 wherein the first and second primary windings are coupled to the external source by a boost converter that is configured to bidirectionally convert a DC power level.

4. The vehicle of claim 1 wherein each of the first and fourth secondary windings is selectively electrically coupled to the traction battery by an inverter that is configured to bidirectionally convert power between direct current (DC) and alternating current (AC).

5. The vehicle of claim 1 wherein the port is selectively electrically coupled to the auxiliary battery by an inverter that is configured to bidirectionally convert power between direct current (DC) at the auxiliary battery and alternating current (AC) at the port.

6. The vehicle of claim 1 wherein the hybrid transformer is configured to, responsive to the first and second primary windings being coupled to the external source and the external source providing power, transfer power to the traction battery via each of the first and fourth secondary windings and provide no power to the auxiliary battery via the port.

7. The vehicle of claim 1 wherein the hybrid transformer is configured to, responsive to selectively coupling the traction battery to the first secondary winding configured to electro-magnetically couple to the first primary winding to provide an alternating current (AC) voltage, output AC voltage to the external source via the first primary winding and to the auxiliary battery via the port.

8. The vehicle of claim 1 wherein the hybrid transformer is configured to, responsive to selectively coupling the traction battery to the first and fourth secondary windings to provide an alternating current (AC) voltage such that the AC voltage provided to the first secondary winding configured to electro-magnetically couple to the first primary winding is 180 degrees out of phase with the AC voltage provided to the fourth secondary winding configured to electro-magnetically couple to the second primary winding, output AC voltage to the auxiliary battery via the port and provide AC voltage to the first and second primary windings such that a voltage across the series combination of the first and second primary windings is zero.

9. A vehicle power distribution system comprising:
a hybrid transformer including first and second primary windings directly coupled in series with opposite polarity to a first port that is selectively electrically couplable to an external source, the first and second primary windings being respectively coupled with a first secondary winding and a fourth secondary winding, and the first and second primary windings being respectively coupled with a second secondary winding and a third secondary winding, wherein the first and fourth secondary windings are selectively electrically coupled to a traction battery, and the second and third secondary windings are directly coupled in series with same polarity to define a second port that is selectively electrically coupled to an auxiliary battery.

10. The vehicle power distribution system of claim 9 further comprising an onboard charger including at least one bidirectional AC/DC conversion stage for selectively electrically coupling the first port to the external source.

11. The vehicle power distribution system of claim 9 further comprising a first inverter circuit for selectively coupling the first secondary winding configured to electro-magnetically couple to the first primary winding to the traction battery, a second inverter circuit for selectively coupling the fourth secondary winding configured to electro-magnetically couple to the second primary winding to the traction battery, and a third inverter circuit for selectively coupling the second port to the auxiliary battery.

12. The vehicle power distribution system of claim 9 wherein the hybrid transformer is configured to, responsive to the first port being selectively coupled to the external source and the external source providing power, transfer power to the traction battery via the first and fourth secondary windings and provide zero power to the auxiliary battery via the second port.

13. The vehicle power distribution system of claim 9 wherein the hybrid transformer is configured to, responsive to selectively coupling the traction battery to the first secondary winding configured to electro-magnetically couple to the first primary winding, transfer power to the external source via the first port and to the auxiliary battery via the second port.

14. The vehicle power distribution system of claim 9 wherein the hybrid transformer is configured to, responsive to selectively coupling the traction battery to the first and fourth secondary windings such that voltages supplied to the first and fourth secondary windings are 180 degrees out of phase with one another, transfer power to the auxiliary battery via the second port and provide zero power to the to the first port.

15. The vehicle power distribution system of claim 9 wherein the first primary winding and corresponding first secondary winding are characterized by a turns ratio that has a same value as the turns ratio that characterizes the second primary winding and corresponding fourth secondary winding.

16. The vehicle power distribution system of claim 9 wherein a turns ratio that characterizes the first primary winding and corresponding second secondary winding has a same value as the turns ratio that characterizes the second primary winding and corresponding third secondary winding.

17. An integrated vehicle power distribution module comprising:
a transformer;
a charger coupled to a series combination with opposite voltage polarity of first and second primary windings of the transformer;
first and second inverters coupled between a traction battery and first and fourth secondary windings configured to electro-magnetically couple to each of the primary windings; and
a third inverter coupled between an auxiliary battery and second and third secondary windings configured to electro-magnetically couple to each of the primary windings, the second and third secondary windings being directly connected in series with same voltage polarities.

18. The integrated vehicle power distribution module of claim 17 wherein the transformer is configured to, responsive to the charger being coupled to an external source and the external source providing power, transfer power to the first and second inverters via the first and fourth secondary windings such that zero power is transferred to the third inverter.

19. The integrated vehicle power distribution module of

Assignees

• Ford Global Tech Llc

Inventors

• Malek Hadi
• Yang Shuitao
• Lathrop James A
• Ferrel Mark J

Classifications

• H02J2207/20

  Charging or discharging characterised by the power electronics converter · CPC title

• H02J7/02 Primary

  for charging batteries from AC mains by converters · CPC title

• B60L53/20 Primary

  characterised by converters located in the vehicle · CPC title

• H02M1/007

  Plural converter units in cascade (push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826) · CPC title

• H02J7/00

  Circuit arrangements for charging or discharging batteries or for supplying loads from batteries · CPC title