Charging device for a motor vehicle

Patent metadata

Field	Value
Publication number	US-12549107-B2
Application number	US-201916287039-A
Country	US
Kind code	B2
Filing date	Feb 27, 2019
Priority date	Mar 6, 2018
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

A charging device for a motor vehicle, having a charging terminal for the energetic coupling to a motor-vehicle-external charging station, a high-voltage terminal for the electrical connection of the charging device to a high-voltage vehicle electrical system of the motor vehicle, and a charging device energy converter electrically coupled to the charging terminal and the high-voltage terminal. The charging device energy converter, for converting electrical energy between the charging terminal and the high-voltage terminal, has an electrical inductor as an electrical energy accumulator, which is at least partially formed as an electronic main coil. A low-voltage terminal for connection to a low-voltage vehicle electrical system of the motor vehicle and an electronic auxiliary coil, which is magnetically coupled to the main coil and electrically coupled to the low-voltage terminal and which is designed to provide electrical energy for the low-voltage vehicle electrical system.

First claim

The invention claimed is:

1 . A charging device for a motor vehicle, comprising:
a charging terminal for an energetic coupling to a motor-vehicle-external charging station, a high-voltage terminal for the electrical connection of the charging device to a high-voltage vehicle electrical system of the motor vehicle, a low-voltage terminal for connection to a low-voltage vehicle electrical system of the motor vehicle, a charging device energy converter electrically coupled to the charging terminal, the high-voltage terminal, and the low-voltage terminal, a step-down converter which connects the high-voltage terminal to the low-voltage terminal on a side of the charging device energy converter opposite to that of the charging terminal, and a detector unit, which is designed to detect the energetic coupling of the charging device to the motor-vehicle-external charging station and to output a corresponding charging signal, wherein, during a driving operation, the step-down converter is enabled so as to allow for the low-voltage vehicle electrical system to be supplied with electricity by the high-voltage vehicle electrical system, and, during a charging operation and upon receipt of the charging signal, the step-down converter is disabled, wherein the charging device energy converter has an electrical inductance as an electrical energy accumulator for converting electrical energy between the charging terminal, the high voltage terminal, and the low voltage terminal, the electrical inductance at least partially formed as an electronic main coil, the electronic main coil having a main coil circuit, wherein the electrical inductance is designed as a transformer, and a primary winding of the transformer forms a first part of the main coil circuit, wherein the main coil comprises a second part connected in parallel to the primary winding so that an energy supply of the low-voltage vehicle electrical system may be flexibly adapted to a coupling dependent on a desired power to be provided, wherein the electrical inductance further comprises an electronic auxiliary coil which is magnetically coupled to the main coil, electrically coupled to the low-voltage terminal, and designed to provide electrical energy for the low-voltage vehicle electrical system, wherein the electronic auxiliary coil is connected via an auxiliary rectifier to the low-voltage terminal, and the main coil is coupled via a main rectifier to the high-voltage terminal, wherein the main rectifier and the auxiliary rectifier each are configured to provide additional voltage adaptation, wherein the charging terminal comprises an electrical coil for inductive coupling with the motor-vehicle-external charging station, wherein, during the charging operation, the low-voltage vehicle electrical system is kept in an operationally ready state which consumes approximately ten percent or less of an expected power load of the low-voltage system during at least the driving operation, wherein the step-down converter is sized to efficiently convert energy at the expected power load and the electronic auxiliary coil is sized to efficiently convert energy for the operationally ready state, and wherein the charging device further comprises a third rectifier that interfaces with the charging terminal and is situated between an EMC (electromagnetic compatibility) filter and a PFC (power factor control) step-up converter.

2 . The charging device as claimed in claim 1 , wherein at least a part of the main coil as well as the electronic auxiliary coil are provided by an electrical transformer.

3 . The charging device as claimed in claim 1 , wherein the charging device energy converter is designed to electrically isolate the charging terminal, the high-voltage terminal and/or the low-voltage terminal from one another.

4 . The charging device as claimed in claim 1 , wherein the electronic auxiliary coil is designed for a rated power which is adapted to a total power of the low-voltage vehicle electrical system during charging operation of the charging device.

5 . The charging device as claimed in claim 1 , wherein the main rectifier and the auxiliary rectifier are each coupled to a respective energy accumulator consisting of an inductor or a capacitor.

6 . The charging device as claimed in claim 1 , wherein the main rectifier and the auxiliary rectifier each comprise at least one controllable semiconductor.

7 . The charging device as claimed in claim 1 , wherein the charging device energy converter operates at a frequency of approximately 100 kHz.

8 . The charging device as claimed in claim 1 , wherein the charging device energy converter operates at a frequency of approximately 500 kHz.

9 . The charging device as claimed in claim 1 , wherein the charging device energy converter operates at a frequency of approximately 1 MHz.

10 . The charging device as claimed in claim 1 , wherein the operationally ready state corresponds to a power of approximately 200 W, and the expected power load is more than approximately 2 kW.

11 . The charging device as claimed in claim 1 , wherein each of the main coil and the electronic auxiliary coil are provided with separate ferromagnetic yokes which are then magnetically coupled to each other.

12 . A motor vehicle, comprising:
a high-voltage vehicle electrical system, a low-voltage vehicle electrical system, a charging device which has a high-voltage terminal connected to the high-voltage vehicle electrical system, a low-voltage terminal connected to the low-voltage vehicle electrical system, a charging terminal for an energetic coupling to a motor-vehicle-external charging station, and an electrical inductance as an electrical energy accumulator, the electrical inductance at least partially formed as an electronic main coil, the electronic main coil having a main coil circuit, and a step-down converter which connects the high-voltage terminal to the low-voltage terminal on a side of the charging device opposite to that of the charging terminal, and a detector unit, which is designed to detect the energetic coupling of the charging device to the motor-vehicle-external charging station and to output a corresponding charging signal, wherein, during a driving operation, the step-down converter is enabled so as to allow for the low-voltage vehicle electrical system to be supplied with electricity by the high-voltage vehicle electrical system, and, during a charging operation and upon receipt of the charging signal, the step-down converter is disabled, wherein the electrical inductance is designed as a transformer, and a primary winding of the transformer forms a first part of the main coil circuit, wherein the main coil comprises a second part connected in parallel to the primary winding so that an energy supply of the low-voltage vehicle electrical system may be flexibly adapted to a coupling dependent on a desired power to be provided, wherein the electrical inductance further comprises an electronic auxiliary coil electronic which is magnetically coupled to the main coil, electrically coupled to the low-voltage terminal, and designed to provide electrical energy for the low-voltage vehicle electrical system, wherein the electronic auxiliary coil is connected via an auxiliary rectifier to the low-voltage terminal, and the main coil is coupled via a main rectifier to the high-voltage terminal, wherein the main rectifier and the auxiliary rectifier each are configured to provide additional voltage adaptation, wherein the charging terminal comprises an electrical coil for inductive coupling with the motor-vehicle-external charging station, wherein, during the charging oper

Assignees

• Audi Ag

Inventors

• Ruppert Daniel

Classifications

• H02M3/33573

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

• H02M3/01

  Resonant DC/DC converters · CPC title

• H02M1/4225

  using a non-isolated boost converter · CPC title

• Y02T10/7072

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

• H02M1/007

  Plural converter units in cascade (push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826) · CPC title