Voltage conversion system for battery electric powertrain with common minus-pole

Patent metadata

Field	Value
Publication number	US-12401215-B2
Application number	US-202217652052-A
Country	US
Kind code	B2
Filing date	Feb 22, 2022
Priority date	Mar 1, 2021
Publication date	Aug 26, 2025
Grant date	Aug 26, 2025

Abstract

An electric vehicle charging system is provided. In some embodiments, the electric vehicle charging system can comprise an electric motor drive system comprising a three-phase electric motor and an inverter. In various embodiments, a negative cable can be connected to an electric vehicle inlet and a battery. In further embodiments, a booster charging cable can be connected to a star-point of the three-phase electric motor and to a positive pole of the electric vehicle inlet, wherein the booster charging cable bypasses a connection between the positive pole and the battery.

First claim

What is claimed is:

1. An electric vehicle charging system, comprising:
an electric motor drive system comprising a three-phase electric motor and an inverter, wherein the inverter comprises a first inverter switch and a second inverter switch;
a negative cable connected to a negative pole of an electric vehicle inlet, the first inverter switch, and a negative pole of a battery;
a booster charging cable connected to a star-point of the three-phase electric motor and to a positive pole of the electric vehicle inlet, wherein the booster charging cable is not connected to the second inverter switch; and
a positive cable connected to the positive pole of the electric vehicle inlet, the second inverter switch, and a positive pole of the battery, wherein the positive cable is not connected to the star-point of the three-phase electric motor,
wherein a first breaker is in line with the negative cable, wherein the first breaker when open is configured to disconnect the negative pole of the electric vehicle inlet from the first inverter switch and the negative pole of a battery,
wherein a second breaker comprising a high voltage charging breaker is in line with the positive cable, wherein the second breaker when open is configured to disconnect the positive pole of the electric vehicle inlet from the second inverter switch and the positive pole of the battery,
wherein a third breaker comprising a charging station voltage charging breaker is on the booster charging cable between the positive pole of the electric vehicle inlet and the star-point of the three-phase electric motor, wherein the third breaker when open is configured to disconnect the positive pole of the electric vehicle inlet from the star-point of the three-phase electric motor, and
wherein the booster charging cable bypasses the positive cable based on respective settings of the first breaker, the second breaker, and the third breaker in response to the electric vehicle inlet being supplied an input voltage that is lower than a voltage of the battery.

2. The electric vehicle charging system of claim 1 , wherein a fourth breaker is in line with the negative cable, and wherein the fourth breaker when open is configured to disconnect the negative pole of the battery from the negative pole of the electric vehicle inlet and the first inverter switch.

3. The electric vehicle charging system of claim 2 , wherein the input voltage comprises 500 volts, and wherein the battery comprises an 800 volt battery.

4. The electric vehicle charging system of claim 1 , wherein the electric vehicle charging system is configured to charge the battery by closing the first breaker, opening the second breaker, and closing the third breaker in response to the electric vehicle inlet being supplied the input voltage that is lower than the voltage of the battery.

5. The electric vehicle charging system of claim 1 , wherein the first breaker, the second breaker, and the third breaker are opened during driving of a vehicle comprising the electric vehicle charging system.

6. The electric vehicle charging system of claim 1 , further comprising a filter capacitor connected between the first breaker and the second breaker.

7. The electric vehicle charging system of claim 1 , wherein the electric motor drive system comprises a filter capacitor and a breaker connected between the negative cable and the star-point of the three-phase electric motor.

8. The electric vehicle charging system of claim 1 , wherein the electric motor drive system comprises an electromagnetic interference filter.

9. An electric vehicle, comprising:
an electric motor drive system comprising a three-phase electric motor and an inverter, wherein the inverter comprises a first inverter switch and a second inverter switch;
a negative cable connected to a negative pole of an electric vehicle inlet, the first inverter switch, and a negative pole of a battery;
a booster charging cable connected to a star-point of the three-phase electric motor and to a positive pole of the electric vehicle inlet, wherein the booster charging cable is not connected to the second inverter switch; and
a positive cable connected to the positive pole of the electric vehicle inlet, the second inverter switch, and a positive pole of the battery, wherein the positive cable is not connected to the star-point of the three-phase electric motor,
wherein a first breaker is in line with the negative cable, wherein the first breaker when open is configured to disconnect the negative pole of the electric vehicle inlet from the first inverter switch and the negative pole of a battery,
wherein a second breaker comprising a high voltage charging breaker is in line with the positive cable, wherein the second breaker when open is configured to disconnect the positive pole of the electric vehicle inlet from the second inverter switch and the positive pole of the battery,
wherein a third breaker comprising a charging station voltage charging breaker is on the booster charging cable between the positive pole of the electric vehicle inlet and the star-point of the three-phase electric motor, wherein the third breaker when open is configured to disconnect the positive pole of the electric vehicle inlet from the star-point of the three-phase electric motor, and
wherein the booster charging cable bypasses the positive cable based on respective settings of the first breaker, the second breaker, and the third breaker in response to the electric vehicle inlet being supplied an input voltage that is lower than a voltage of the battery.

10. The electric vehicle of claim 9 , wherein the first breaker, the second breaker, and the third breaker are opened during driving of the electric vehicle.

11. The electric vehicle of claim 9 , wherein the electric vehicle charging system is configured to charge the battery by closing the first breaker, opening the second breaker, and closing the third breaker in response to the electric vehicle inlet being supplied the input voltage that is lower than the voltage of the battery.

12. The electric vehicle of claim 9 , wherein the electric motor drive system comprises an electromagnetic interference filter.

13. The electric vehicle of claim 9 , wherein a fourth breaker is in line with the negative cable, and wherein the fourth breaker when open is configured to disconnect the negative pole of the battery from the negative pole of the electric vehicle inlet and the first inverter switch.

14. The electric vehicle of claim 9 , wherein the electric motor drive system comprises an 800 volt electric motor drive system.

15. A method, comprising:
determining, by a system comprising a processor, a maximum voltage of a battery of an electric vehicle and a voltage supplied to an inlet of the electric vehicle, wherein the electric vehicle comprises:
an electric motor drive system comprising a three-phase electric motor, a first inverter switch, and a second inverter switch;
a negative cable connected to a negative pole of an electric vehicle inlet, the first inverter switch, and a negative pole of the battery;
a booster charging cable connected to a star-point of the three-phase electric motor and to a positive pole of the electric vehicle inlet, wherein the booster charging cable is not connected to the second inverter switch; and
a positive cable connected to the positive pole of the electric vehicle inlet, the second inverter switch, and a positive pole of the battery, wherein the positive cable is not connected to the star-point of the three-phase electric motor; and

in response to a determination, by the system, that the maximum voltage of t

Assignees

• Volvo Car Corp

Inventors

• Lasson Nils Anders
• Gannamaneni Narendar Rao
• Sjöstedt Lars Johan Henrik

Classifications

• H02J7/60

  including safety or protection arrangements · CPC title

• H02J7/96 Primary

  in response to battery voltage · CPC title

• H02P27/06

  using DC to AC converters or inverters (H02P27/05 takes precedence) · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M10/48

  Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte (constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569) · CPC title