Automotive integrated on-board charger using inverter and motor windings

Patent metadata

Field	Value
Publication number	US-2025050760-A1
Application number	US-202318448473-A
Country	US
Kind code	A1
Filing date	Aug 11, 2023
Priority date	Aug 11, 2023
Publication date	Feb 13, 2025
Grant date	—

Abstract

An automotive on-board charger topology includes an inverter, an electric machine, and a rectifier that together perform functions such as power factor correction usually performed by a collection of multiple components. This topology also includes a set of contactors that isolate a battery from other components of the charger based on the contactors' configuration.

First claim

What is claimed is:

1 . An automotive on-board charger comprising:
a battery; an inverter; a rectifier; an electric machine, including windings, connected between the inverter and rectifier; and a controller programmed to operate the inverter such that the inverter, windings, and rectifier together shift a phase between a voltage and current of power from a grid to alter a power factor of the power.

2 . The automotive on-board charger of claim 1 further comprising a transformer, including at least one contactor, connected between the battery and inverter.

3 . The automotive on-board charger of claim 2 , wherein the transformer is configured such that when the at least one contactor is in a predefined state, the battery and inverter are connected.

4 . The automotive on-board charger of claim 2 , wherein the transformer further includes a plurality of switches and wherein the controller is programmed to operate the switches in a predefined pattern to alter the voltage to charge the battery.

5 . The automotive on-board charger of claim 1 , wherein the inverter includes a plurality of switches and wherein the controller is further programmed to operate the switches such that the inverter transforms DC power from the battery to AC power for the electric machine.

6 . The automotive on-board charger of claim 1 , wherein the inverter is configured to transform AC power from the electric machine to DC power for the battery.

7 . The automotive on-board charger of claim 1 , wherein the inverter is an n-phase inverter.

8 . The automotive on-board charger of claim 1 , wherein the rectifier is a diode rectifier.

9 . The automotive on-board charger of claim 1 , wherein the rectifier is an n-phase rectifier.

10 . The automotive on-board charger of claim 1 , wherein the electric machine is a motor.

11 . A method comprising:
responsive to receiving input power from an AC grid, operating a plurality of switches of an inverter such that the inverter, a rectifier, and windings of an electric machine, that is connected between the rectifier and inverter, together shift a phase between a voltage and current of the input power to alter a power factor of the input power.

12 . The method of claim 11 further comprising, while connected to the AC grid, opening at least one contactor such that a power output from the inverter passes through a transformer prior to delivery to a battery.

13 . The method of claim 11 further comprising while disconnected from the AC grid, closing at least one contactor to connect a battery to the electric machine.

14 . A vehicle comprising:
a power system including a battery, an inverter, a rectifier, a transformer, an electric machine connected between the inverter and the rectifier, and a controller programmed to during charge, operate the inverter to alter a power factor of power from a grid via the inverter, the rectifier, and windings of the electric machine, and after the charge, close at least one contactor such that power between the battery and the inverter bypass the transformer.

15 . The vehicle of claim 14 , wherein the controller is further programmed to, when preparing to charge, open the at least one contactor such that a power from the grid will pass through the transformer.

16 . The vehicle of claim 14 , wherein the transformer further includes a plurality of switches and wherein the controller is further programmed to operate the switches in a predefined pattern to alter a voltage delivered to the battery during the charge.

17 . The vehicle of claim 14 , wherein the inverter includes a plurality of switches and wherein the controller is further programmed to operate the switches such that the inverter transforms DC power from the battery to AC power for the electric machine.

18 . The vehicle of claim 14 , wherein the inverter is an n-phase inverter.

19 . The vehicle of claim 14 , wherein the electric machine is a motor.

20 . The vehicle of claim 14 , wherein the rectifier is an n-phase rectifier.

Assignees

• Ford Global Tech Llc

Inventors

• Taskas Petros G
• Ge Baoming

Classifications

• B60L15/007

  Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles · CPC title

• B60L53/22 Primary

  Constructional details or arrangements of charging converters specially adapted for charging electric vehicles · CPC title

• B60L53/14

  Conductive energy transfer · CPC title

• B60L2210/30

  AC to DC converters · CPC title

• B60L2210/40

  DC to AC converters · CPC title