Fast charger protection under sudden stop conditions

Patent metadata

Field	Value
Publication number	US-12545137-B2
Application number	US-202318228092-A
Country	US
Kind code	B2
Filing date	Jul 31, 2023
Priority date	Jul 31, 2023
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

Systems and methods for operating a PEM including control circuitry are provided herein. The operation includes detecting, using the control circuitry, a drop in output current of the PEM, detecting, using the control circuitry, an increase in output voltage of the PEM, and in response to detecting the drop in output current and detecting the increase in output voltage, turning off the PEM using the control circuitry. Turning off the PEM may protect circuitry of the PEM from an interruption of a continuous power flow.

First claim

What is claimed is:

1 . A method comprising:
detecting, using control circuitry, a drop in output current of a power electronics module (PEM); in response to detecting the drop in the output current, detecting, using the control circuitry, whether an output voltage of the PEM increases over a period of time; and in response to detecting that the output voltage increased over the period of time, turning off the PEM using the control circuitry.

2 . The method of claim 1 , wherein the PEM comprises a DC-DC converter.

3 . The method of claim 2 , wherein the DC-DC converter comprises a dual active bridge converter.

4 . The method of claim 3 , wherein turning off the PEM comprises turning off a switching element of the dual active bridge converter.

5 . The method of claim 1 , wherein:
turning off the first PEM protects circuity of the PEM from an interruption of a continuous power flow; and the interruption is based on an interruption of one or more of a physical connection or an electrical connection between an electric vehicle charging port and a dispenser of the PEM.

6 . The method of claim 1 , wherein:
the PEM is a first PEM electrically coupled in parallel to a second PEM; the first and second PEMs are configured to provide a net positive DC output current; the drop in output current of the first PEM results in a negative output current; and the method further comprises, in response to detecting the negative output current, turning off the first PEM using the control circuitry.

7 . The method of claim 6 , wherein a main controller monitors the first and second PEMs, the method further comprising:
transmitting a first PEM status signal to the main controller based on the first PEM being turned off; and in response to receiving the first PEM status signal, notifying, using the main controller, an external device of the first PEM status signal.

8 . The method of claim 1 , wherein the output current is coupled to at least one of an energy storage device or a DC-AC converter.

9 . A method comprising:
detecting, using control circuitry, a negative current at an output of a first power electronics module (PEM), wherein the first PEM is electrically coupled in parallel to a second PEM to provide a net positive DC output current; in response to detecting the negative current at the output of the first PEM, detecting, using the control circuitry, whether a net output voltage of the first PEM and the second PEM increases over a period of time; and in response to detecting that the net output voltage increased over the period of time, turning off the first PEM using the control circuitry.

10 . The method of claim 9 , wherein:
a main controller monitors the first and second PEMs;
the turning off of the first PEM further comprises transmitting a first PEM status signal to the main controller; and
in response to receiving the first PEM status signal, the main controller notifies an external device of the first PEM status signal.

11 . The method of claim 9 , wherein each PEM comprises a DC-DC converter, and each DC-DC converter comprises a dual active bridge converter.

12 . The method of claim 9 , wherein the net positive DC output current is coupled to at least one of an energy storage device or a DC-AC converter.

13 . A system comprising:
a power electronics module (PEM); and control circuitry of the PEM configured to:
detect a drop in output current of the PEM;
in response to detecting the drop in the output current, detect whether an output voltage of the PEM increases over a period of time; and
in response to detecting that the output voltage increased over the period of time, turn off the PEM.

14 . The system of claim 13 , wherein the PEM comprises a DC-DC converter.

15 . The system of claim 14 , wherein the DC-DC converter comprises a dual active bridge converter.

16 . The system of claim 15 , wherein the control circuitry is configured to turn off the PEM by causing a switching element of the dual active bridge converter to turn off.

17 . The system of claim 13 , further comprising:
a main controller coupled to the PEM and at least one additional PEM, wherein:
the control circuitry of the PEM is further configured to transmit a PEM status signal to the main controller based on the PEM being turned off; and
in response to receiving the PEM status signal, the main controller is configured to notify an external device of the PEM status signal.

18 . The system of claim 13 , wherein the PEM is a first PEM coupled in parallel to a second PEM to provide a net positive DC output current and wherein the control circuitry of the first PEM is further configured to:
detect a negative current at an output of the first PEM; and in response to detecting the negative output current, turn off the first PEM.

19 . The system of claim 18 , wherein the negative output current of the first PEM occurs when a load stops receiving the net positive DC output current and the second PEM continues providing a positive DC output current and wherein the control circuitry of the first PEM is configured such that turning off the first PEM protects circuity of the first PEM from an interruption of a continuous power flow.

20 . The system of claim 13 , wherein the output current is coupled to at least one of an energy storage device or a DC-AC converter.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Murthy Puneeth Srikanta
• Wei Lixiang
• Schulz Steven

Classifications

• H02H3/18

  responsive to reversal of direct current · CPC title

• H02H7/1252

  responsive to overvoltage in input or output, e.g. by load dump · CPC title

• H02H7/1213

  for DC-DC converters · CPC title

• H02H3/38

  responsive to both voltage and current; responsive to phase angle between voltage and current · CPC title

• H02H3/12

  responsive to underload or no-load {(for motors H02H7/0827)} · CPC title