Motor drive integrated on-board charger for electric vehicle and control method thereof

Patent metadata

Field	Value
Publication number	US-2024157823-A1
Application number	US-202218282203-A
Country	US
Kind code	A1
Filing date	Mar 18, 2022
Priority date	Mar 18, 2021
Publication date	May 16, 2024
Grant date	—

Abstract

The present disclosure provides a motor drive integrated on-board charger to reduce the quantity of components in an electric system of an electric vehicle. Reduction of components is achieved by utilizing the motor and the motor driving inverter as a part of the on-board charger in the charging mode. By controlling relays, electrical connections of the system may be reconfigured according to its mode of operation. In one aspect, the motor and the motor driving inverter play the roles of a boost PFC, a current regulator, or both.

First claim

What is claimed is:

1 . An electric system of an electric vehicle, comprising:
an AC/DC converter; a motor drive comprising a motor and an inverter; a power factor correcting (PFC) inductor electrically connected between the AC/DC converter and the motor drive; a link capacitor connected in parallel with the motor drive; a first relay connected between the PFC inductor and the motor drive; and a second relay through which a battery is connected to the link capacitor.

2 . The electric system of claim 1 , wherein the motor comprises a plurality of phases, and the inverter comprises a plurality of phase legs, each first end of the phases being connected to a respective one of the phase legs.

3 . The electric system of claim 2 , wherein second ends of the phases are connected at a neutral point.

4 . The electric system of claim 2 , wherein the PFC inductor is connected to a selected one of the phase legs through the first relay.

5 . The electric system of claim 2 , wherein each of the phase legs comprises two switches and the PFC inductor is connected to a terminal between the two switches of a selected one of the phase legs through the first relay.

6 . The electric system of claim 1 , wherein in a driving mode, the first relay is opened and the second relay is closed, and the battery is capable of being discharged to power the motor; and/or in a charging mode, the first relay and the second relay are closed, and the battery is capable of being charged using an AC power source.

7 . (canceled)

8 . The electric system of claim 1 , wherein the AC/DC converter comprises a resonant converter, capable of receiving an AC power source at an input terminal and generating a DC power at an output terminal.

9 . The electric system of claim 1 , wherein the AC/DC converter comprises one of an isolated AC/DC rectifier having a half bridge inverter and a full bridge rectifier, an isolated AC/DC rectifier having a full bridge inverter and a full bridge rectifier, an isolated AC/DC rectifier having a half bridge inverter and a voltage doubler rectifier, and an isolated AC/DC rectifier having a full bridge inverter and a voltage doubler rectifier.

10 . An electric system of an electric vehicle, comprising:
an AC/DC converter; a motor drive including a motor and an inverter, wherein the motor comprises a plurality of phases and the inverter comprises a plurality of phase legs, each of the phases being connected to a respective one of the phase legs; a power factor correcting (PFC) inductor electrically connected between the AC/DC converter and the motor drive; a link capacitor connected in parallel with the motor drive; a first relay configured to selectively connect a selected one of the phase legs either to a respective one of the phases of the motor or to the PFC inductor; and a second relay configured to selectively connect a battery either to a positive terminal of the inverter or to said respective one of the phases of the motor.

11 . The electric system of claim 10 , wherein each of the phase legs comprises two switches and the first relay is connected between the PFC inductor and a terminal between the two switches of said selected one of the phase legs.

12 . The electric system of claim 11 , wherein one ends of the phase legs are connected together at a neutral point.

13 . (canceled)

14 . The electric system of claim 10 , wherein in a driving mode, the first relay connects said selected one of the phase legs to said respective one of the phases of the motor, the second relay connects the battery to the positive terminal of the inverter, and the battery is capable of being discharged to power the motor; and/or in a charging mode, the first relay connects said selected one of the phase legs to the PFC inductor, and the second relay connects the battery to said respective one of the phases of the motor, and the battery is capable of being charged using an AC power source.

15 . (canceled)

16 . The electric system of claim 10 , wherein the AC/DC converter comprises a resonant converter, capable of receiving an AC power source at an input terminal and generating a DC power at an output terminal.

17 . The electric system of claim 10 , wherein the AC/DC converter comprises one of an isolated AC/DC rectifier having a half bridge inverter and a full bridge rectifier, an isolated AC/DC rectifier having a full bridge inverter and a full bridge rectifier, an isolated AC/DC rectifier having a half bridge inverter and a voltage doubler rectifier, and an isolated AC/DC rectifier having a full bridge inverter and a voltage doubler rectifier.

18 . An electric system of an electric vehicle, comprising:
an AC/DC converter; a motor drive including a motor and an inverter, wherein the motor comprises a plurality of phases and the inverter comprises a plurality of phase legs, each of the phases being connected to a respective one of the phase legs; a power factor correcting (PFC) inductor electrically connected between the AC/DC converter and the motor drive; a link capacitor connected in parallel with the motor drive; a first relay connected between a selected one of the phase legs and a respective one of the phases; a second relay configured to connect or disconnect said selected one of the phase legs with the PFC inductor and configured to connect or disconnect said respective one of the phases with a buffer capacitor; and a third relay through which a battery is connected to the link capacitor.

19 . The electric system of claim 18 , wherein the second relay comprises a double-pole double-throw relay.

20 . The electric system of claim 18 , wherein in a driving mode, the first and third relays are closed and the second relay is opened, and the battery is capable of being discharged to power the motor; and/or in a charging mode, the second and third relays are closed and the first relay is opened, and the battery is capable of being charged using an AC power source.

21 . (canceled)

22 . An electric system of an electric vehicle, comprising:
an AC/DC converter capable of receiving an AC power source at an input terminal of the AC/DC converter and providing a DC power at an output terminal of the AC/DC converter; a first relay electrically connected to the output terminal of the AC/DC converter; a motor connected to the AC/DC converter through the first relay and comprising a plurality of phase legs with one end of the phase legs being connected at a neutral point, wherein the first relay is connected to the neutral point; a motor driving inverter connected to the motor; a link capacitor connected in parallel with the motor driving inverter; and a second relay through which the link capacitor is connected to a battery.

23 . The electric system of claim 22 , wherein in a driving mode, the first relay is opened and the second relay is closed, and the battery is capable of being discharged to power the motor; and/or in a charging mode, the first relay and the second relay are closed, and the battery is capable of being charged using an AC power source.

24 . (canceled)

25 . (canceled)

26 . The electric system of claim 22 further comprises a third relay electrically connected to the first relay, the motor, and the motor driving inverter.

27 . The electric system of claim 26 , wherein the motor comprises a plurality of phases, the motor driving

Assignees

• Delta Electronics Inc

Inventors

• Sadilek Tomas
• Wang Ruxi
• Mukherjee Satyaki
• Lin Hui-Hsin
• Wei Chung-Hwa
• Barbosa Peter Mantovanelli

Classifications

• H02J7/855

  with circuits adapted for supplying loads from the battery · CPC title

• H02J2105/37

  exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV] · CPC title

• B60L2210/10

  DC to DC converters · CPC title

• H02M3/1584

  with a plurality of power processing stages connected in parallel · CPC title

• H02M3/1582

  Buck-boost converters (H02M3/1584 takes precedence) · CPC title