Active discharge of an electric drive system

Patent metadata

Field	Value
Publication number	US-12323052-B2
Application number	US-202217665249-A
Country	US
Kind code	B2
Filing date	Feb 4, 2022
Priority date	Feb 18, 2021
Publication date	Jun 3, 2025
Grant date	Jun 3, 2025

Abstract

Systems, devices, and methods for active discharge of an electric drive system for a vehicle includes an inverter having at least one phase leg, wherein a first of the phase legs includes a first power switch, a dc/dc converter configured to generate an internal supply voltage that is regulated with respect to a voltage on a rail, and a gate drive channel configured to drive the first power switch into conductance by applying a relatively high voltage difference during operation of the vehicle and to continue the driving of the first power switch with a relatively lower voltage difference after a signal indicating shut-down or fault. The dc/dc converter is configured to generate the internal supply voltage to have either a relatively high voltage difference with respect to the voltage on the rail or a relatively lower voltage difference with respect to the voltage on the rail.

First claim

What is claimed is:

1. An electric drive system for a vehicle, the electric drive system comprising:
an inverter having at least one phase leg, wherein a first of the at least one phase leg includes a first power switch;
a dc/dc converter configured to generate an internal supply voltage that is regulated with respect to a voltage on a rail configured to be coupled to a dc power supply, wherein the dc/dc converter is configured to generate the internal supply voltage to have either a relatively high voltage difference with respect to the voltage on the rail or a relatively lower voltage difference with respect to the voltage on the rail in response to a discharge command; and
a gate drive channel configured to drive the first power switch into conductance by applying a relatively high voltage difference derived from the internal supply voltage during operation of the vehicle and to continue the driving of the first power switch with a relatively lower voltage difference derived from the internal supply voltage after a signal indicating shut-down or fault of the vehicle.

2. The electric drive system of claim 1 , wherein the dc/dc converter comprises:
a transistor bridge; and
a bridge controller coupled to receive the discharge command and, in response, configured to switch from driving the transistor bridge as a full bridge to driving the transistor bridge as a half bridge.

3. The electric drive system of claim 1 , wherein the gate drive channel is configured to pulse the first power switch after the signal indicating the shut-down or the fault of the vehicle.

4. The electric drive system of claim 3 , wherein the gate drive channel is configured to pulse the first power switch for a time duration defined with respect to a time needed to discharge a capacitance coupled across the at least one phase leg of the inverter.

5. The electric drive system of claim 3 , wherein the gate drive channel comprises gate drive circuitry having desaturation protection circuitry, wherein the desaturation protection circuitry specifies when conduction of the first power switch is to end during the pulsing.

6. The electric drive system of claim 1 , wherein the dc/dc converter further comprises:
a capacitor; and
a transformer with an input winding and an output winding, wherein the capacitor is coupled to the input winding of the transformer.

7. The electric drive system of claim 1 , wherein:
the first of the at least one phase leg comprises a second power switch; and
the gate drive channel is further configured to drive the second power switch for a time duration.

8. The electric drive system of claim 7 , wherein the gate drive channel is configured to drive the second power switch with a higher transconductance than a transconductance of the first power switch for the time duration.

9. The electric drive system of claim 1 , wherein the electric drive system is housed in a vehicle.

10. A control system configured to control a power switch that comprises a first terminal, a second terminal, and a control terminal, wherein conductance between the first and second terminals of the power switch is responsive to a difference between a voltage on the control terminal and a voltage on the second terminal, wherein the control system comprises:
a supply capacitor coupled between a positive rail and a negative rail of the control system;
a dc/dc converter configured to detect a discharge command in the control system, wherein the discharge command initiates active discharge of the supply capacitor, the dc/dc converter configured to switch from generating an internal supply voltage with a relatively higher voltage difference to generating the supply voltage with a relatively lower voltage difference, wherein the dc/dc converter is configured to output a signal indicative of the internal supply voltage falling below a threshold; and
a switch controller coupled to receive the signal indicative of the internal supply voltage falling below a threshold, wherein the switch controller is configured to control the difference between the voltage on the control terminal and the voltage on the second terminal based on the supply voltage with a relatively lower voltage difference in response to the signal indicative of the internal supply voltage falling below the threshold.

11. The control system of claim 10 , wherein the dc/dc converter comprises:
a transistor bridge; and
a bridge controller coupled to receive the discharge command and, in response, configured to switch from driving the transistor bridge as a full bridge to driving the transistor bridge as a half bridge.

12. The control system of claim 10 , wherein the discharge command is a shut-down command.

13. The control system of claim 10 , wherein the switch controller is configured to receive a high level command and convert the high level command into a switching pattern for controlling the difference between the voltage on the control terminal and the voltage on the second terminal.

14. The control system of claim 10 , wherein the switch controller comprises gate drive circuitry having desaturation protection circuitry, wherein the desaturation protection circuitry specifies when conduction of the power switch is to end during the active discharge.

15. The control system of claim 10 , wherein the dc/dc converter is configured to output an undervoltage signal to indicate the internal supply voltage falling below the threshold.

16. The control system of claim 10 , wherein the power switch is part of a phase leg of an inverter that has a plurality of phase legs.

17. The control system of claim 10 , wherein the control system is housed in a vehicle.

Assignees

• Power Integrations Inc

Inventors

• Volke Andreas
• Maurer Vinzenz
• Abid Salem
• Hagglund Douglas Arnold Erik Andersson
• Hornkamp Michael
• Peter Matthias

Classifications

• B60L3/04 Primary

  Cutting off the power supply under fault conditions (protective devices and circuit arrangements in general H01H; H02H) · CPC title

• B60L3/0046

  relating to electric energy storage systems, e.g. batteries or capacitors · CPC title

• H02M3/33573

  Full-bridge at primary side of an isolation transformer · CPC title

• H02M7/5387

  in a bridge configuration · CPC title

• H02M3/01

  Resonant DC/DC converters · CPC title