Charging system of an electric vehicle using traction inverter and electric machine

Patent metadata

Field	Value
Publication number	US-12420655-B2
Application number	US-202217587681-A
Country	US
Kind code	B2
Filing date	Jan 28, 2022
Priority date	Mar 1, 2021
Publication date	Sep 23, 2025
Grant date	Sep 23, 2025

Abstract

An electric vehicle charging system is provided. In some embodiments, the electric vehicle charging system can comprise a three-phase electric motor and an inverter. The inverter can be connected to the three-phase electric motor and to a battery. In various implementations, the inverter can comprise a switch and a capacitor. In further implementations, the switch can close to precharge a capacitor to a defined fraction of a voltage of the battery.

First claim

What is claimed is:

1. An electric vehicle charging system, comprising:
a controller, comprising a processor;
a three-phase electric motor; and
an inverter connected to the three-phase electric motor and to a battery, wherein the inverter comprises a switch, a bypass switch, a capacitor pre-charge switch, and a capacitor,
wherein the capacitor pre-charge switch is located between a positive terminal of a charging station and the switch, closable based on a type of the charging station,
wherein the controller closes the switch to pre-charge the capacitor via the battery using the inverter and the three-phase electric motor in a buck mode, to a defined fraction of a voltage of the battery, in response to a determination, by the controller, that the charging station connected to an electric vehicle comprises a maximum output voltage lower than a maximum voltage of the battery,
wherein the controller closes the bypass switch to charge the battery directly from the charging station, without using the three-phase electric motor and the inverter for a boost operation, in response to a determination that the maximum voltage of the battery is lower than or equal to the maximum output voltage of the charging station,
wherein the battery is charged using the capacitor, inverter, and three-phase electric motor when the charging station comprises an output voltage lower than the voltage of the battery, and
wherein based on a type of the charging station, the controller closes the capacitor pre-charge switch:
in response to a determination that the capacitor has been pre-charged to a voltage difference of less than or equal to 20V of the output voltage of the charging station, or
in response to a determination that the capacitor has been pre-charged to at least half of the voltage of the battery.

2. The electric vehicle charging system of claim 1 , wherein the defined fraction comprises ½ the voltage of the battery.

3. The electric vehicle charging system of claim 1 , wherein the inverter is connected to the charging station.

4. The electric vehicle charging system of claim 1 , wherein the charging station comprises a 400 volt charging station, and wherein the battery comprises an 800 volt battery.

5. The electric vehicle charging system of claim 1 , wherein the inverter comprises a duty ratio of 50%.

6. An electric vehicle, comprising:
a three-phase electric motor;
an inverter connected to the three-phase electric motor and to a battery, wherein the inverter comprises a switch, a bypass switch, a capacitor pre-charge switch, and a capacitor; and
a controller, comprising a processor,
wherein the capacitor pre-charge switch is located between a positive terminal of a charging station and the switch, closable based on a type of the charging station,
wherein the controller closes the switch to precharge the capacitor via the battery using the inverter and the three-phase electric motor in a buck mode, to a defined fraction of a voltage of the battery in response to a determination, by the controller, that the charging station connected to the electric vehicle comprises a maximum output voltage lower than a maximum voltage of the battery,
wherein the controller closes the bypass switch to charge the battery directly from the charging station, without using the three-phase electric motor and the inverter for a boost operation, in response to a determination that the maximum voltage of the battery is lower than or equal to the maximum output voltage of the charging station,
wherein the battery is charged using the capacitor, inverter, and three-phase electric motor when the charging station comprises an output voltage lower than the voltage of the battery, and
wherein based on a type of the charging station, the controller closes the capacitor pre-charge switch:
in response to a determination that the capacitor has been pre-charged to a voltage difference of less than or equal to 20V of the output voltage of the charging station, or
in response to a determination that the capacitor has been pre-charged to at least half of the voltage of the battery.

7. The electric vehicle of claim 6 , wherein
the three-phase electric motor and the inverter operate as a direct current to direct current booster in a first power flow direction, wherein the first power flow direction comprises a direction for transmitting power from the charging station to the battery; and
the three-phase electric motor and the inverter operate as a buck direct current to direct current converter in a second power flow direction, wherein the second power flow direction comprises a direction for transmitting power supplied by the battery to the capacitor.

8. The electric vehicle of claim 7 , wherein
in the first power flow direction, the capacitor is connected in parallel to the three-phase electric motor and the inverter operating as the direct current to direct current booster; and
in the second power flow direction, the capacitor is connected in series with the inverter and the three-phase electric motor operating as a buck direct current to direct current converter.

9. The electric vehicle of claim 6 , wherein the inverter comprises a three-phase inverter.

10. The electric vehicle of claim 9 , wherein the capacitor is connected to a neutral circuit of the three-phase electric motor and each phase the three-phase electric motor is connected to a respective phase of the inverter.

11. The electric vehicle of claim 6 , wherein the inverter comprises at least six semi-conductor switches.

12. The electric vehicle of claim 11 , wherein the at least six semi-conductor switches comprise insulated-gate bipolar transistors or silicon carbide metal-oxide-semiconductor field-effect transistors.

13. The electric vehicle of claim 6 , wherein the defined fraction comprises ½ the voltage of the battery.

14. The electric vehicle of claim 6 , wherein the inverter comprises a duty ratio of 50%.

15. A vehicle, comprising:
a three-phase electric motor;
an inverter connected to the three-phase electric motor and to a battery, wherein the inverter comprises a switch, a bypass switch, a capacitor pre-charge switch, and a capacitor; and
a controller, comprising a processor,
wherein the a capacitor pre-charge switch is located between a positive terminal of a charging station and the switch, closable based on a type of the charging station,
wherein the controller closes the switch to pre-charge the capacitor via the battery using the inverter and the three-phase electric motor in a buck mode, to a defined fraction of a voltage of the battery, in response to a determination, by the controller, that the charging station connected to the vehicle comprises a maximum output voltage lower than a maximum voltage of the battery,
wherein the controller closes the bypass switch to charge the battery directly from the charging station, without using the three-phase electric motor and the inverter for a boost operation, in response to a determination that the maximum voltage of the battery is lower than or equal to the maximum output voltage of the charging station, and
wherein the battery is charged using the capacitor, inverter, and three-phase electric motor when the charging station comprises an output voltage lower than the voltage of the battery, and
wherein based on a type of the charging station, the controller closes the capacitor pre-charge switch:
in response to a determination that the capacitor has been pre-charged to a voltage difference of less than or equal to 20V of the output voltage of the charging station, or
in response to a determination that the

Assignees

• Volvo Car Corp

Inventors

• Gannamaneni Narendar Rao
• Sjöstedt Lars Johan Henrik
• Ådahl Andreas Lars Bertil

Classifications

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title

• Y02T10/7072

  Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors · CPC title

• H02J7/345

  using capacitors as storage or buffering devices · CPC title

• B60L2210/12

  Buck converters · CPC title

• H02J2207/20

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