Converter system for transferring power

Patent metadata

Field	Value
Publication number	US-12508927-B2
Application number	US-202217964098-A
Country	US
Kind code	B2
Filing date	Oct 12, 2022
Priority date	Oct 18, 2021
Publication date	Dec 30, 2025
Grant date	Dec 30, 2025

Abstract

A converter system for transferring power, including a first high voltage DC-DC module, a second high voltage DC-DC module, and a controller. The high voltage DC-DC modules are electrically separated, the first high voltage DC-DC module is connected to a first high voltage interface of a high voltage system and to a first low voltage interface of a low voltage system, and being of a first DC-DC module type, and the second high voltage DC-DC module is connected to a second high voltage interface of the high voltage system and to a second low voltage interface of the low voltage system, and being of a second different DC-DC module type. The controller is configured to control power supply via one of the high voltage DC-DC modules to the low voltage system in case of failure affecting the other one of the high voltage DC-DC modules.

First claim

The invention claimed is:

1 . A converter system for transferring power, comprising:
a first high voltage DC-DC module; a second high voltage DC-DC module; and a controller; the first high voltage DC-DC module and the second high voltage DC-DC module being electrically separated from each other; the first high voltage DC-DC module being connected to a first high voltage interface of a high voltage system and to a first low voltage interface of a low voltage system; the second high voltage DC-DC module being connected to a second high voltage interface of the high voltage system and to a second low voltage interface of the low voltage system, and differing from the first high voltage DC-DC module in at least one hardware feature; and the controller being configured to control power supply via one of the first high voltage DC-DC module and the second high voltage DC-DC module to the low voltage system in case of failure affecting the other one of the first high voltage DC-DC module and the second high voltage DC-DC module; and an AC-DC module being connected to a third high voltage interface and to a fourth high voltage interface of the high voltage system, being configured to supply power to the high voltage system, and being electrically separated from the first high voltage DC-DC module and the second high voltage DC-DC module.

2 . The converter system of claim 1 , the first high voltage DC-DC module being configured bidirectional to selectively supply power from the first high voltage interface to the first low voltage interface or vice versa.

3 . The converter system of claim 1 , the first high voltage DC-DC module being configured single-stage and to regulate power supply to the first low voltage interface.

4 . The converter system of claim 1 , the second high voltage DC-DC module being configured unidirectional to supply power from the second high voltage interface to the second low voltage interface.

5 . The converter system of claim 1 , the second high voltage DC-DC module being configured multi-stage and comprising a first regulator stage connected to the high voltage system and configured to regulate its output to a fixed value and a second, fixed-ratio stage connected to the regulator stage to be fed with the output of the regulator stage, and the controller being further configured to control power supply via the second high voltage DC-DC module to the low voltage system in case of failure affecting the first high voltage DC-DC module.

6 . The converter system of claim 1 , the controller being further configured to control the second high voltage DC-DC module to supply power to the low voltage system and to turn off power supply by the first high voltage DC-DC module in case of failure causing high voltage of the high voltage system to decrease.

7 . The converter system of claim 1 , further comprising at least one high voltage contactor configured to selectively connect or disconnect the AC-DC module with the high voltage system via the respective third high voltage interface and/or fourth high voltage interface.

8 . The converter system of claim 1 , further comprising at least one low power DC-DC module being connected in parallel with one of the first high voltage DC-DC module and the second high voltage DC-DC module and configured to supply power to the low voltage system if the converter system or a parent system comprising it is in a non-operating mode.

9 . The converter system of claim 1 , further comprising a first low power DC-DC module being connected in parallel with the first high voltage DC-DC module and a second low power DC-DC module being connected in parallel with the second high voltage DC-DC module, and one of the first and second low power DC-DC module being configured to supply power to the low voltage system if the converter system or a parent system comprising it is in a non-operating mode.

10 . The converter system of claim 9 , the second low power DC-DC module being connected to the low voltage system via the second high voltage DC-DC module.

11 . A vehicle comprising an electric propulsion machine and the converter system of claim 1 .

12 . The vehicle of claim 11 , further comprising a charging port being connected to the AC-DC module of the converter system.

13 . The vehicle of claim 11 , further comprising a first high voltage battery arrangement and a second high voltage battery arrangement together forming a high voltage system of the vehicle, the first high voltage battery arrangement being connected to a first high voltage interface and the second high voltage battery arrangement being connected to a second high voltage interface of the converter system.

14 . A method for controlling a converter system, comprising:
selectively connecting a high voltage system and a low voltage system with each other via at least one of a first high voltage DC-DC module of a first type and a second high voltage DC-DC module of a second type different to the first type to control power supply from the high voltage system to the low voltage system; the selectively connecting the high voltage system and the low voltage system with each other comprises at least one of: in case of non-failure operating mode, connecting the high voltage system and the low voltage system with each other via both the first high voltage DC-DC module and the second high voltage DC-DC module, in case of a non-operating mode, connecting the high voltage system and the low voltage system with each other via at least one low power DC-DC module being connected in parallel with one of the first high voltage DC-DC module and the second high voltage DC-DC module, thereby bypassing the respective first high voltage DC-DC module or second high voltage DC-DC module, and in case of failure affecting one of the first high voltage DC-DC module and the second high voltage DC-DC module, connecting the high voltage system and the low voltage system with each other via the other, non-affected one of the first high voltage DC-DC module and the second high voltage DC-DC module; and selectively connecting an AC-DC module to the high voltage system, being configured to supply power to the high voltage system, and being electrically separated from the first high voltage DC-DC module and the second high voltage DC-DC module.

Assignees

• Volvo Car Corp

Inventors

• Gannamaneni Narendar Rao
• Dareini Ali

Classifications

• B60L2220/40

  Electrical machine applications · CPC title

• B60L2210/30

  AC to DC converters · CPC title

• B60L2210/10

  DC to DC converters · CPC title

• B60L53/16

  Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles · CPC title

• B60L50/66

  Arrangements of batteries · CPC title