WO2022015519A1 - Bidirectional electric vehicle charging with multi-phase machines - Google Patents

Bidirectional electric vehicle charging with multi-phase machines Download PDF

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Publication number
WO2022015519A1
WO2022015519A1 PCT/US2021/040114 US2021040114W WO2022015519A1 WO 2022015519 A1 WO2022015519 A1 WO 2022015519A1 US 2021040114 W US2021040114 W US 2021040114W WO 2022015519 A1 WO2022015519 A1 WO 2022015519A1
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WO
WIPO (PCT)
Prior art keywords
phases
phase machine
controller
electric grid
grid
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2021/040114
Other languages
French (fr)
Inventor
Oliver D. WILSON
Akm Arafat
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cummins Inc
Original Assignee
Cummins Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cummins Inc filed Critical Cummins Inc
Priority to US18/015,457 priority Critical patent/US12077056B2/en
Priority to CN202180048986.8A priority patent/CN115803219A/en
Priority to EP21841631.1A priority patent/EP4182182A4/en
Publication of WO2022015519A1 publication Critical patent/WO2022015519A1/en
Anticipated expiration legal-status Critical
Priority to US18/792,221 priority patent/US20240391336A1/en
Ceased legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/66Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal
    • H02M7/68Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters
    • H02M7/72Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/79Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/797Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/20Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by converters located in the vehicle
    • B60L53/24Using the vehicle's propulsion converter for charging
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L55/00Arrangements for supplying energy stored within a vehicle to a power network, i.e. vehicle-to-grid [V2G] arrangements
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J3/00Circuit arrangements for AC mains or AC distribution networks
    • H02J3/28Arrangements for balancing of the load in networks by storage of energy
    • H02J3/32Arrangements for balancing of the load in networks by storage of energy using batteries or super capacitors with converting means
    • H02J3/322Arrangements for balancing of the load in networks by storage of energy using batteries or super capacitors with converting means the battery being on-board an electric or hybrid vehicle, e.g. vehicle to grid arrangements [V2G], power aggregation, use of the battery for network load balancing, coordinated or cooperative battery charging
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or discharging batteries or for supplying loads from batteries
    • H02J7/02Circuit arrangements for charging or discharging batteries or for supplying loads from batteries for charging batteries from AC mains by converters
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/42Conversion of DC power input into AC power output without possibility of reversal
    • H02M7/44Conversion of DC power input into AC power output without possibility of reversal by static converters
    • H02M7/48Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2210/00Converter types
    • B60L2210/40DC to AC converters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2220/00Electrical machine types; Structures or applications thereof
    • B60L2220/50Structural details of electrical machines
    • B60L2220/54Windings for different functions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2220/00Electrical machine types; Structures or applications thereof
    • B60L2220/50Structural details of electrical machines
    • B60L2220/58Structural details of electrical machines with more than three phases
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2105/00Networks for supplying or distributing electric power characterised by their spatial reach or by the load
    • H02J2105/30Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles
    • H02J2105/33Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles exchanging power with road vehicles
    • H02J2105/37Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles exchanging power with road vehicles exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV]
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2207/00Details of circuit arrangements for charging or discharging batteries or supplying loads from batteries
    • H02J2207/20Charging or discharging characterised by the power electronics converter
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/66Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal
    • H02M7/68Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters
    • H02M7/72Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/79Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/81Conversion of AC power input into DC power output; Conversion of DC power input into AC power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal arranged for operation in parallel
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/64Electric machine technologies in electromobility
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/70Energy storage systems for electromobility, e.g. batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/80Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
    • Y02T10/92Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/14Plug-in electric vehicles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y04INFORMATION OR COMMUNICATION TECHNOLOGIES HAVING AN IMPACT ON OTHER TECHNOLOGY AREAS
    • Y04SSYSTEMS INTEGRATING TECHNOLOGIES RELATED TO POWER NETWORK OPERATION, COMMUNICATION OR INFORMATION TECHNOLOGIES FOR IMPROVING THE ELECTRICAL POWER GENERATION, TRANSMISSION, DISTRIBUTION, MANAGEMENT OR USAGE, i.e. SMART GRIDS
    • Y04S10/00Systems supporting electrical power generation, transmission or distribution
    • Y04S10/12Monitoring or controlling equipment for energy generation units, e.g. distributed energy generation [DER] or load-side generation
    • Y04S10/126Monitoring or controlling equipment for energy generation units, e.g. distributed energy generation [DER] or load-side generation the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]

Definitions

  • the present disclosure generally relates to multi-phase electric machines, and more particularly to techniques for bidirectional charging of electric vehicles using multi-phase electric machines.
  • Multi-phase electric machines are utilized in various applications including electric vehicles.
  • a drive system of an electric vehicle typically includes an alternating current (AC) electric motor driven by a direct current (DC) power source (e.g., a main battery).
  • the AC electric motor is coupled to the DC power source via an inverter which performs switching functions to convert the DC power to AC power.
  • the DC power source is a rechargeable energy storage device that needs to be replenished periodically.
  • the DC power source is charged by connecting to a power grid using additional hardware (e.g., rectifiers, converters, protection circuits, etc.), which often results in increased cost and weight to the electric vehicle. Accordingly, there remains a need to develop other techniques for charging electric vehicles such as by utilizing multi phase electric machines.
  • the present disclosure provides a system for bidirectional charging in an electric vehicle.
  • the system includes a multi-phase machine, and a controller coupled to the multi-phase machine.
  • the controller is configured to receive a first request for energy flow from an electric grid to the electric vehicle.
  • the controller is also configured to operate a first set of phases in the multi-phase machine through a first inverter.
  • the controller is configured to switch the first set of phases in the multi-phase machine to the electric grid.
  • the controller In response to switching the first set of phases in the multi-phase machine to the electric grid, the controller is configured to operate a second set of phases in the multi-phase machine through a second inverter, where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine.
  • the controller is also configured to provide the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
  • the present disclosure provides a controller for bidirectional charging in an electric vehicle.
  • the controller includes a processor and a memory.
  • the memory includes instructions that, when executed by the processor, cause the controller to receive a first request for energy flow from an electric grid to the electric vehicle.
  • the electric vehicle includes a multi-phase machine.
  • the processor also causes the controller to operate a first set of phases in the multi-phase machine through a first inverter. In response to the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid, the processor causes the controller to switch the first set of phases in the multi-phase machine to the electric grid.
  • the processor In response to switching the first set of phases in the multi-phase machine to the electric grid, the processor causes the controller to operate a second set of phases in the multi phase machine through a second inverter, where the second set of phases in the multi phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine.
  • the processor also causes the controller to provide the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
  • the present disclosure provides a method for bidirectional charging in an electric vehicle.
  • the method includes determining a direction of energy flow between the electric vehicle and an electric grid.
  • the electric vehicle includes a multi-phase machine.
  • the method includes operating a first set of phases in the multi-phase machine through a first inverter.
  • the method includes switching the first set of phases in the multi-phase machine to the electric grid.
  • the method includes operating a second set of phases in the multi-phase machine through a second inverter, where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine.
  • the method also includes providing the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
  • the controller in response to determining that the direction of energy flow is from the electric vehicle to the electric grid, the controller operates the second set of phases in the multi-phase machine through the second inverter. In certain embodiments, in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, the controller switches the first set of phases in the multi-phase machine to the electric grid, where the first set of phases in the multi-phase machine generates energy via electrical coupling to the second set of phases in the multi-phase machine and the energy generated by the first set of phases in the multi phase machine is provided to the electric grid.
  • operating the first set of phases in the multi-phase machine through the first inverter includes closing a first set of switches to connect the first set of phases in the multi-phase machine to the first inverter.
  • the first set of phases in the multi-phase machine in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, is isolated from the first inverter by opening the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter.
  • connecting the first set of phases in the multi-phase machine to the electric grid includes closing a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
  • the multi-phase machine is a six-phase machine with each of the first set of phases and the second set of phases being a three- phase system.
  • FIG. l is a block diagram illustrating a system for bidirectional charging of an electric vehicle
  • FIGS. 2 and 3 are block diagrams illustrating operations to provide energy from an electric grid to the electric vehicle of FIG. 1;
  • FIGS. 4 and 5 are block diagrams illustrating operations to provide energy from the electric vehicle of FIG. 1 to an electric grid
  • FIG. 6 is a flow chart illustrating a method for operating the electric vehicle of FIG. 1 for bidirectional charging.
  • Coupled is used to include both arrangements wherein two or more components are in direct physical contact and arrangements wherein the two or more components are not in direct contact with each other (e.g., the components are “coupled” via at least a third component), but yet still cooperate or interact with each other.
  • numeric terminology such as first and second, is used in reference to various components or features. Such use is not intended to denote an ordering of the components or features. Rather, numeric terminology is used to assist the reader in identifying the component or features being referenced and should not be narrowly interpreted as providing a specific order of components or features.
  • One of ordinary skill in the art will realize that the embodiments provided can be implemented in hardware, software, firmware, and/or a combination thereof. Programming code according to the embodiments can be implemented in any viable programming language such as C, C++, HTML, XTML, JAVA or any other viable high- level programming language, or a combination of a high-level programming language and a lower level programming language.
  • An electric vehicle needs external power to recharge its energy storage system (e.g., vehicle-to-grid (V2G) charging).
  • V2G vehicle-to-grid
  • a six- phase motor system is provided to accomplish this by synchronizing a six-phase motor to a three-phase power grid.
  • the six-phase motor is configured in two three-phase stages. One of the three-phase stages is isolated from the system and connected to the power grid. The other of the three-phase stages is placed into a regeneration mode to draw power from the motor.
  • This interfacing scheme eliminates the need for additional hardware to interface with the power grid when charging the electric vehicle.
  • the six-phase motor system operates over a range of grid frequencies and voltages, which adds versatility to the electric vehicle.
  • the six-phase motor system provides isolation between the electric vehicle’s DC system and the AC power grid, which reduces electrical emissions and enhances safety.
  • the six-phase motor system is bidirectional allowing the electric vehicle to temporarily connect to and supply energy to the power grid.
  • the electric vehicle can be converted for stationary energy storage and power conditioning applications with minimal modifications.
  • the six-phase motor system provides advantages by eliminating additional hardware to thereby provide cost savings and weight reductions in the electric vehicle, while enhancing the electric vehicle’s performance and safety.
  • Electric vehicle 102 includes, among other things, a multi-phase AC machine 106, inverters 108, 110, a controller 112, a DC bus 114, and a battery bank 116.
  • a multi-phase AC machine 106 for inverters 108, 110
  • a controller 112 for inverters 108, 110
  • a DC bus 114 for DC bus 116
  • battery bank 116 for ease of illustration, other components of electric vehicle 102 (e.g., transmission, brakes, wheels, etc.) are not shown, the operations of which are known to those skilled in the art.
  • the term “electric vehicle” refers to any vehicle that is partly or entirely operated based on stored electric power such as a pure electric vehicle, a hybrid electric vehicle, or the like.
  • Such vehicles can include road vehicles (e.g., cars, trucks, buses, etc.), rail vehicles, underwater vessels, aircrafts, and other suitable vehicles.
  • multi-phase AC machine 106 is a motor used to provide torque in electric vehicle 102.
  • motor 106 is a six-phase asymmetric permanent magnet synchronous AC motor.
  • AC machine refers to an AC powered device that converts electrical energy to mechanical energy or vice versa.
  • motor 106 has six windings 107A-107F, with each being associated with a respective phase of motor 106.
  • Motor 106 is set up like two three- phase systems electrically coupled to each other.
  • a first set of phases include windings 107A-107C
  • a second set of phases include windings 107D-107F.
  • the two sets of phases or windings are shifted from one another by a phase value (e.g., 30 degrees, 60 degrees, etc.).
  • the phase value is 30 degrees
  • the first and second sets of phases are asymmetric in nature.
  • two individual three- phase motors may be used as motor 106.
  • Windings 107A-107F represent a stator of motor 106.
  • stator and other components e.g., rotor, shaft, etc.
  • the rotor is mounted to the shaft and the rotor is separated from the stator by an air gap.
  • the stator causes the rotor to rotate utilizing electrical energy thereby rotating the shaft to provide mechanical energy.
  • the shaft is rotated by an external mechanical force that causes the rotor to rotate thereby causing the stator to generate electrical energy.
  • Controller 112 operates motor 106 via respective inverters 108, 110.
  • controller 112 receives operating signals from motor 106 and generates control signals to control the switching operations of inverters 108, 110 respectively to thereby control the outputs (e.g., currents) provided to windings 107A-107F.
  • Inverters 108, 110 include, among other things, switching devices (e.g., transistors, diodes, etc.) to appropriately switch DC voltages and provide energization to windings 107A-107F as known to those skilled in the art.
  • switching devices e.g., transistors, diodes, etc.
  • inverters 108, 110 may be pulse width modulated inverters. While FIG. 1 shows inverters 108, 110 as being separate three-phase inverters that each control a respective winding group, in some embodiments, windings 107A-107F may be controlled by using a single six-phase inverter.
  • controller 112 may be part of inverter 108 and/or inverter 110.
  • Inverters 108, 110 are connected to battery bank 116 (e.g., lithium-ion battery packs) via DC bus 114, which includes one or more DC bus capacitors 118.
  • battery bank 116 e.g., lithium-ion battery packs
  • DC bus 114 which includes one or more DC bus capacitors 118.
  • Battery bank 116 acts as an energy source of electric vehicle 102 which needs to be replenished periodically. To do so, electric vehicle 102 is plugged into an outlet 120 of electric grid 104 to allow energy (e.g., electricity) to flow between electric vehicle 102 and electric grid 104.
  • energy e.g., electricity
  • controller 112 includes a non-transitory memory having instructions that, in response to execution by a processor, cause the processor to perform the functions of controller 112 as described herein.
  • the processor, non-transitory memory and controller 112 are not particularly limited and can, for example, be physically separate.
  • controller 112 forms a portion of a processing subsystem including one or more computing devices having memory, processing, and communication hardware.
  • controller 112 can be a single device or a distributed device, and functions of controller 112 can be performed by hardware and/or as computer instructions on a non-transient computer readable storage medium, such as the non-transitory memory.
  • controller 112 includes one or more interpreters, determiners, evaluators, regulators, and/or processors that functionally execute the operations of controller 112.
  • Interpreters, determiners, evaluators, regulators, and processors can be implemented in hardware and/or as computer instructions on a non transient computer readable storage medium and can be distributed across various hardware or computer-based components.
  • FIGS. 2 and 3 are block diagrams illustrating the transfer of energy from electric grid 104 to electric vehicle 102. This represents charging/recharging schemes for electric vehicle 102. To do so, controller 112 determines that the direction of energy flow is from electric grid 104 to electric vehicle 102. For example, controller 112 may receive an input from a user (e.g., an operator of electric vehicle 102) indicating that battery bank 116 needs to be charged. As an example, a monitoring device in electric vehicle 102 (e.g., a battery management system (BMS)) may signal to controller 112 that battery bank 116 has been depleted and thus needs recharging.
  • BMS battery management system
  • controller 112 initiates operation of the first set of phases (e.g., 107A-107C) in motor 106 through inverter 108. As shown in FIG. 2, controller 112 sends a control signal 202 to close first set of switches 122 but open second set of switches 124. This connects the first set of phases (e.g., 107A-107C) in motor 106 to inverter 108. Controller 112 operates the first set of phases (e.g., 107A-107C) in motor 106 up to a grid frequency (e.g., 60 Hz) of electric grid 104. In some embodiments, controller 112 operates the first set of phases (e.g., 107A-107C) in motor 106 according to other properties of electric grid 104 (e.g., voltage, phase angle, etc.).
  • other properties of electric grid 104 e.g., voltage, phase angle, etc.
  • controller 112 When the first set of phases (e.g., 107A-107C) in motor 106 is operating at the grid frequency, controller 112 enables a connection between the first set of phases (e.g., 107A-107C) in motor 106 and electric grid 104 via outlet 120. As shown in FIG. 3, controller 112 sends control signal 202 to disconnect the first set of phases (e.g., 107A- 107C) in motor 106 from inverter 108 by opening first set of switches 122. At the same time, controller 112 uses control signal 202 to connect the first set of phases (e.g., 107A- 107C) in motor 106 to outlet 120 by closing second set of switches 124.
  • the first set of phases e.g., 107A-107C
  • electric grid 104 provides energy to the first set of phases
  • controller 112 operates the second set of phases (e.g., 107D-107F) in motor 106 through inverter 110 in a regeneration mode to draw power or energy from the first set of phases (e.g., 107A-107C) in motor 106. Controller 112 then provides the energy generated by the second set of phases (e.g., 107D- 107F) in motor 106 to battery bank 116 via DC bus 114 to recharge battery bank 116.
  • FIGS. 4 and 5 are block diagrams illustrating the transfer of energy from electric vehicle 102 to electric grid 104. This represents grid assist and/or grid forming schemes for electric grid 104. To do so, controller 112 determines that the direction of energy flow is from electric vehicle 102 to electric grid 104. For example, controller 112 may receive an input from a user or operator of electric vehicle 102 indicating that electric vehicle 102 has capacity to share or contribute energy to electric grid 104.
  • controller 112 To begin transferring energy from electric vehicle 102 to electric grid 104, controller 112 initiates operation of the second set of phases (e.g., 107D-107F) in motor 106 through inverter 110. As shown in FIG. 4, controller 112 sends control signal 202 to open first and second sets of switches 122, 124, while operating the second set of phases (e.g., 107D-107F) in motor 106 up to the grid frequency of electric grid 104. In some embodiments, controller 112 operates the second set of phases (e.g., 107D-107F) in motor 106 in accordance with other properties of electric grid 104.
  • the second set of phases e.g., 107D-107F
  • controller 112 When the second set of phases (e.g., 107D-107F) in motor 106 is operating at the grid frequency, controller 112 enables a connection between the first set of phases (e.g., 107A-107C) in motor 106 and electric grid 104 via outlet 120. As shown in FIG. 5, controller 112 sends control signal 202 to connect the first set of phases (e.g., 107A-107C) in motor 106 to outlet 120 by closing second set of switches 124. The first set of phases (e.g., 107A-107C) in motor 106 generates energy via electrical coupling to the second set of phases (e.g., 107D-107F) in motor 106.
  • the first set of phases e.g., 107A-107C
  • the first set of phases (e.g., 107A- 107C) in motor 106 draws power or energy from the second set of phases (e.g., 107D- 107F) in motor 106 in a regeneration mode.
  • the energy generated by the first set of phases (e.g., 107A-107C) in motor 106 is provided or supplied to electric grid 104.
  • FIG. 6 a method 600 for operating an electric vehicle
  • method 600 is performed by a controller (e.g., 112).
  • the controller determines a direction of energy flow between the electric vehicle and an electric grid.
  • the electric vehicle includes a multi phase machine (e.g., 106).
  • the multi-phase machine is a six-phase machine with a first set of phases (e.g., 107A-107C) and a second set of phases (e.g., 107D-107F) each being a three-phase system.
  • the controller in response to the controller determining that the direction of energy flow is from the electric grid to the electric vehicle (e.g., the controller receives a first request for energy flow from the electric grid to the electric vehicle), the controller operates the first set of phases in the multi-phase machine through a first inverter (e.g., 108), where the first set of phases in the multi-phase machine is operated at a grid frequency of the electric grid.
  • operating the first set of phases in the multi-phase machine through the first inverter includes closing a first set of switches (e.g., 122) to connect the first set of phases in the multi-phase machine to the first inverter.
  • the controller switches the first set of phases in the multi-phase machine to the electric grid.
  • the controller isolates the first set of phases in the multi phase machine from the first inverter by opening the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter.
  • connecting the first set of phases in the multi-phase machine to the electric grid includes closing a second set of switches (e.g., 124) to connect the first set of phases in the multi-phase machine to the electric grid.
  • the controller in response to switching the first set of phases in the multi phase machine to the electric grid, operates the second set of phases in the multi-phase machine through a second inverter (e.g., 110), where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine.
  • the controller provides the energy generated by the second set of phases in the multi-phase machine to charge an energy source (e.g., 116) of the electric vehicle.
  • the controller in response to the controller determining that the direction of energy flow is from the electric vehicle to the electric grid (e.g., the controller receives a second request for energy flow from the electric vehicle to the electric grid), the controller operates the second set of phases in the multi-phase machine through a second inverter (e.g., 110), where the second set of phases in the multi-phase machine is operated at the grid frequency of the electric grid.
  • a second inverter e.g., 110
  • the controller switches the first set of phases in the multi-phase machine to the electric grid, where the first set of phases in the multi-phase machine generates energy via electrical coupling to the second set of phases in the multi-phase machine and the energy generated by the first set of phases in the multi-phase machine is then provided to the electric grid.
  • switching the first set of phases in the multi-phase machine to the electric grid includes opening a first set of switches (e.g., 122) to disconnect the first set of phases in the multi phase machine from a first inverter (e.g., 108) and closing a second set of switches (e.g., 124) to connect the first set of phases in the multi-phase machine to the electric grid.
  • a first set of switches e.g., 122
  • a first inverter e.g., 108
  • closing a second set of switches e.g., 124
  • references to “one embodiment,” “an embodiment,” “an example embodiment,” etc. indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic with the benefit of this disclosure in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

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Abstract

A method and system for bidirectional charging in an electric vehicle include controlling a multi-phase machine in the electric vehicle. In response to determining that a direction of energy flow is from an electric grid to the electric vehicle, the method and system include operating a first set of phases in the multi-phase machine at a grid frequency of the electric grid and connecting the first set of phases in the multi-phase machine to the electric grid. In response to connecting the first set of phases in the multi-phase machine to the electric grid, the method and system include operating a second set of phases in the multi-phase machine, where the second set of phases in the multi -phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine. The method and system also include providing the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.

Description

BIDIRECTIONAL ELECTRIC VEHICLE CHARGING WITH MULTI-PHASE
MACHINES
FIELD OF THE DISCLOSURE
[0001] The present disclosure generally relates to multi-phase electric machines, and more particularly to techniques for bidirectional charging of electric vehicles using multi-phase electric machines.
BACKGROUND OF THE DISCLOSURE
[0002] Multi-phase electric machines are utilized in various applications including electric vehicles. For example, a drive system of an electric vehicle typically includes an alternating current (AC) electric motor driven by a direct current (DC) power source (e.g., a main battery). The AC electric motor is coupled to the DC power source via an inverter which performs switching functions to convert the DC power to AC power. The DC power source is a rechargeable energy storage device that needs to be replenished periodically. Typically, the DC power source is charged by connecting to a power grid using additional hardware (e.g., rectifiers, converters, protection circuits, etc.), which often results in increased cost and weight to the electric vehicle. Accordingly, there remains a need to develop other techniques for charging electric vehicles such as by utilizing multi phase electric machines.
SUMMARY
[0003] According to some embodiments, the present disclosure provides a system for bidirectional charging in an electric vehicle. The system includes a multi-phase machine, and a controller coupled to the multi-phase machine. The controller is configured to receive a first request for energy flow from an electric grid to the electric vehicle. The controller is also configured to operate a first set of phases in the multi-phase machine through a first inverter. In response to the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid, the controller is configured to switch the first set of phases in the multi-phase machine to the electric grid. In response to switching the first set of phases in the multi-phase machine to the electric grid, the controller is configured to operate a second set of phases in the multi-phase machine through a second inverter, where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine. The controller is also configured to provide the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
[0004] According to certain embodiments, the present disclosure provides a controller for bidirectional charging in an electric vehicle. The controller includes a processor and a memory. The memory includes instructions that, when executed by the processor, cause the controller to receive a first request for energy flow from an electric grid to the electric vehicle. The electric vehicle includes a multi-phase machine. The processor also causes the controller to operate a first set of phases in the multi-phase machine through a first inverter. In response to the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid, the processor causes the controller to switch the first set of phases in the multi-phase machine to the electric grid.
In response to switching the first set of phases in the multi-phase machine to the electric grid, the processor causes the controller to operate a second set of phases in the multi phase machine through a second inverter, where the second set of phases in the multi phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine. The processor also causes the controller to provide the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
[0005] According to some embodiments, the present disclosure provides a method for bidirectional charging in an electric vehicle. The method includes determining a direction of energy flow between the electric vehicle and an electric grid. The electric vehicle includes a multi-phase machine. In response to determining that the direction of energy flow is from the electric grid to the electric vehicle, the method includes operating a first set of phases in the multi-phase machine through a first inverter. In response to the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid, the method includes switching the first set of phases in the multi-phase machine to the electric grid. In response to switching the first set of phases in the multi phase machine to the electric grid, the method includes operating a second set of phases in the multi-phase machine through a second inverter, where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine. The method also includes providing the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
[0006] In some embodiments, in response to determining that the direction of energy flow is from the electric vehicle to the electric grid, the controller operates the second set of phases in the multi-phase machine through the second inverter. In certain embodiments, in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, the controller switches the first set of phases in the multi-phase machine to the electric grid, where the first set of phases in the multi-phase machine generates energy via electrical coupling to the second set of phases in the multi-phase machine and the energy generated by the first set of phases in the multi phase machine is provided to the electric grid.
[0007] In certain embodiments, operating the first set of phases in the multi-phase machine through the first inverter includes closing a first set of switches to connect the first set of phases in the multi-phase machine to the first inverter. In some embodiments, in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, the first set of phases in the multi-phase machine is isolated from the first inverter by opening the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter. In certain embodiments, connecting the first set of phases in the multi-phase machine to the electric grid includes closing a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid. In some examples, the multi-phase machine is a six-phase machine with each of the first set of phases and the second set of phases being a three- phase system. BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. l is a block diagram illustrating a system for bidirectional charging of an electric vehicle;
[0009] FIGS. 2 and 3 are block diagrams illustrating operations to provide energy from an electric grid to the electric vehicle of FIG. 1;
[0010] FIGS. 4 and 5 are block diagrams illustrating operations to provide energy from the electric vehicle of FIG. 1 to an electric grid; and
[0011] FIG. 6 is a flow chart illustrating a method for operating the electric vehicle of FIG. 1 for bidirectional charging.
DETAILED DESCRIPTION
[0012] For the purposes of promoting an understanding of the principles of the present disclosure, reference is now made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed herein are not intended to be exhaustive or to limit the disclosure to the precise form disclosed in the following detailed description. Rather, these embodiments were chosen and described so that others skilled in the art may utilize their teachings.
[0013] The terms “couples,” “coupled,” and variations thereof are used to include both arrangements wherein two or more components are in direct physical contact and arrangements wherein the two or more components are not in direct contact with each other (e.g., the components are “coupled” via at least a third component), but yet still cooperate or interact with each other.
[0014] Throughout the present disclosure and in the claims, numeric terminology, such as first and second, is used in reference to various components or features. Such use is not intended to denote an ordering of the components or features. Rather, numeric terminology is used to assist the reader in identifying the component or features being referenced and should not be narrowly interpreted as providing a specific order of components or features. [0015] One of ordinary skill in the art will realize that the embodiments provided can be implemented in hardware, software, firmware, and/or a combination thereof. Programming code according to the embodiments can be implemented in any viable programming language such as C, C++, HTML, XTML, JAVA or any other viable high- level programming language, or a combination of a high-level programming language and a lower level programming language.
[0016] An electric vehicle needs external power to recharge its energy storage system (e.g., vehicle-to-grid (V2G) charging). According to various embodiments, a six- phase motor system is provided to accomplish this by synchronizing a six-phase motor to a three-phase power grid. The six-phase motor is configured in two three-phase stages. One of the three-phase stages is isolated from the system and connected to the power grid. The other of the three-phase stages is placed into a regeneration mode to draw power from the motor. This interfacing scheme eliminates the need for additional hardware to interface with the power grid when charging the electric vehicle. The six-phase motor system operates over a range of grid frequencies and voltages, which adds versatility to the electric vehicle.
[0017] Additionally, the six-phase motor system provides isolation between the electric vehicle’s DC system and the AC power grid, which reduces electrical emissions and enhances safety. The six-phase motor system is bidirectional allowing the electric vehicle to temporarily connect to and supply energy to the power grid. In some embodiments, at the end of the electric vehicle’s life, the electric vehicle can be converted for stationary energy storage and power conditioning applications with minimal modifications. The six-phase motor system provides advantages by eliminating additional hardware to thereby provide cost savings and weight reductions in the electric vehicle, while enhancing the electric vehicle’s performance and safety.
[0018] Referring now to FIG. 1, a block diagram of a system 100 for bidirectional charging is shown including an electric vehicle 102 and an electric grid 104 (e.g., a 3-phase distribution grid, a microgrid, etc.). Electric vehicle 102 includes, among other things, a multi-phase AC machine 106, inverters 108, 110, a controller 112, a DC bus 114, and a battery bank 116. For ease of illustration, other components of electric vehicle 102 (e.g., transmission, brakes, wheels, etc.) are not shown, the operations of which are known to those skilled in the art. As used herein, the term “electric vehicle” refers to any vehicle that is partly or entirely operated based on stored electric power such as a pure electric vehicle, a hybrid electric vehicle, or the like. Such vehicles can include road vehicles (e.g., cars, trucks, buses, etc.), rail vehicles, underwater vessels, aircrafts, and other suitable vehicles.
[0019] According to various embodiments, multi-phase AC machine 106 is a motor used to provide torque in electric vehicle 102. For example, motor 106 is a six-phase asymmetric permanent magnet synchronous AC motor. As used herein, the term “AC machine” refers to an AC powered device that converts electrical energy to mechanical energy or vice versa.
[0020] As shown in FIG. 1, motor 106 has six windings 107A-107F, with each being associated with a respective phase of motor 106. Motor 106 is set up like two three- phase systems electrically coupled to each other. For example, a first set of phases include windings 107A-107C, while a second set of phases include windings 107D-107F. The two sets of phases or windings are shifted from one another by a phase value (e.g., 30 degrees, 60 degrees, etc.). As an example, if the phase value is 30 degrees, then the first and second sets of phases are asymmetric in nature. In certain embodiments, two individual three- phase motors may be used as motor 106.
[0021] Windings 107A-107F represent a stator of motor 106. For ease of illustration, the stator and other components (e.g., rotor, shaft, etc.) of motor 106 are not shown. Generally, the rotor is mounted to the shaft and the rotor is separated from the stator by an air gap. When utilized as a motor, the stator causes the rotor to rotate utilizing electrical energy thereby rotating the shaft to provide mechanical energy. On the other hand, when utilized as a generator, the shaft is rotated by an external mechanical force that causes the rotor to rotate thereby causing the stator to generate electrical energy.
[0022] Controller 112 operates motor 106 via respective inverters 108, 110. For example, controller 112 receives operating signals from motor 106 and generates control signals to control the switching operations of inverters 108, 110 respectively to thereby control the outputs (e.g., currents) provided to windings 107A-107F.
[0023] Inverters 108, 110 include, among other things, switching devices (e.g., transistors, diodes, etc.) to appropriately switch DC voltages and provide energization to windings 107A-107F as known to those skilled in the art. As an example, inverters 108, 110 may be pulse width modulated inverters. While FIG. 1 shows inverters 108, 110 as being separate three-phase inverters that each control a respective winding group, in some embodiments, windings 107A-107F may be controlled by using a single six-phase inverter. In certain embodiments, controller 112 may be part of inverter 108 and/or inverter 110.
[0024] Inverters 108, 110 are connected to battery bank 116 (e.g., lithium-ion battery packs) via DC bus 114, which includes one or more DC bus capacitors 118.
Battery bank 116 acts as an energy source of electric vehicle 102 which needs to be replenished periodically. To do so, electric vehicle 102 is plugged into an outlet 120 of electric grid 104 to allow energy (e.g., electricity) to flow between electric vehicle 102 and electric grid 104. By using a first set of switches 122 and a second set of switches 124, energy can flow from electric grid 104 to electric vehicle 102 via motor 106, and from electric vehicle 102 to electric grid 104 via motor 106.
[0025] According to some embodiments, controller 112 includes a non-transitory memory having instructions that, in response to execution by a processor, cause the processor to perform the functions of controller 112 as described herein. The processor, non-transitory memory and controller 112 are not particularly limited and can, for example, be physically separate.
[0026] In certain embodiments, controller 112 forms a portion of a processing subsystem including one or more computing devices having memory, processing, and communication hardware. For example, controller 112 can be a single device or a distributed device, and functions of controller 112 can be performed by hardware and/or as computer instructions on a non-transient computer readable storage medium, such as the non-transitory memory. [0027] In some embodiments, controller 112 includes one or more interpreters, determiners, evaluators, regulators, and/or processors that functionally execute the operations of controller 112. Interpreters, determiners, evaluators, regulators, and processors can be implemented in hardware and/or as computer instructions on a non transient computer readable storage medium and can be distributed across various hardware or computer-based components.
[0028] FIGS. 2 and 3 are block diagrams illustrating the transfer of energy from electric grid 104 to electric vehicle 102. This represents charging/recharging schemes for electric vehicle 102. To do so, controller 112 determines that the direction of energy flow is from electric grid 104 to electric vehicle 102. For example, controller 112 may receive an input from a user (e.g., an operator of electric vehicle 102) indicating that battery bank 116 needs to be charged. As an example, a monitoring device in electric vehicle 102 (e.g., a battery management system (BMS)) may signal to controller 112 that battery bank 116 has been depleted and thus needs recharging.
[0029] To begin transferring energy from electric grid 104 to electric vehicle 102, controller 112 initiates operation of the first set of phases (e.g., 107A-107C) in motor 106 through inverter 108. As shown in FIG. 2, controller 112 sends a control signal 202 to close first set of switches 122 but open second set of switches 124. This connects the first set of phases (e.g., 107A-107C) in motor 106 to inverter 108. Controller 112 operates the first set of phases (e.g., 107A-107C) in motor 106 up to a grid frequency (e.g., 60 Hz) of electric grid 104. In some embodiments, controller 112 operates the first set of phases (e.g., 107A-107C) in motor 106 according to other properties of electric grid 104 (e.g., voltage, phase angle, etc.).
[0030] When the first set of phases (e.g., 107A-107C) in motor 106 is operating at the grid frequency, controller 112 enables a connection between the first set of phases (e.g., 107A-107C) in motor 106 and electric grid 104 via outlet 120. As shown in FIG. 3, controller 112 sends control signal 202 to disconnect the first set of phases (e.g., 107A- 107C) in motor 106 from inverter 108 by opening first set of switches 122. At the same time, controller 112 uses control signal 202 to connect the first set of phases (e.g., 107A- 107C) in motor 106 to outlet 120 by closing second set of switches 124.
[0031] Once connected, electric grid 104 provides energy to the first set of phases
(e.g., 107A-107C) in motor 106, which in turn causes energy to be generated in the second set of phases (e.g., 107D-107F) in motor 106 via electrical coupling to the first set of phases (e.g., 107A-107C) in motor 106. In particular, controller 112 operates the second set of phases (e.g., 107D-107F) in motor 106 through inverter 110 in a regeneration mode to draw power or energy from the first set of phases (e.g., 107A-107C) in motor 106. Controller 112 then provides the energy generated by the second set of phases (e.g., 107D- 107F) in motor 106 to battery bank 116 via DC bus 114 to recharge battery bank 116.
[0032] FIGS. 4 and 5 are block diagrams illustrating the transfer of energy from electric vehicle 102 to electric grid 104. This represents grid assist and/or grid forming schemes for electric grid 104. To do so, controller 112 determines that the direction of energy flow is from electric vehicle 102 to electric grid 104. For example, controller 112 may receive an input from a user or operator of electric vehicle 102 indicating that electric vehicle 102 has capacity to share or contribute energy to electric grid 104.
[0033] To begin transferring energy from electric vehicle 102 to electric grid 104, controller 112 initiates operation of the second set of phases (e.g., 107D-107F) in motor 106 through inverter 110. As shown in FIG. 4, controller 112 sends control signal 202 to open first and second sets of switches 122, 124, while operating the second set of phases (e.g., 107D-107F) in motor 106 up to the grid frequency of electric grid 104. In some embodiments, controller 112 operates the second set of phases (e.g., 107D-107F) in motor 106 in accordance with other properties of electric grid 104.
[0034] When the second set of phases (e.g., 107D-107F) in motor 106 is operating at the grid frequency, controller 112 enables a connection between the first set of phases (e.g., 107A-107C) in motor 106 and electric grid 104 via outlet 120. As shown in FIG. 5, controller 112 sends control signal 202 to connect the first set of phases (e.g., 107A-107C) in motor 106 to outlet 120 by closing second set of switches 124. The first set of phases (e.g., 107A-107C) in motor 106 generates energy via electrical coupling to the second set of phases (e.g., 107D-107F) in motor 106. In particular, the first set of phases (e.g., 107A- 107C) in motor 106 draws power or energy from the second set of phases (e.g., 107D- 107F) in motor 106 in a regeneration mode. In this manner, the energy generated by the first set of phases (e.g., 107A-107C) in motor 106 is provided or supplied to electric grid 104.
[0035] Referring now to FIG. 6, a method 600 for operating an electric vehicle
(e.g., 102) for bidirectional charging is shown. For example, method 600 is performed by a controller (e.g., 112). At block 602, the controller determines a direction of energy flow between the electric vehicle and an electric grid. The electric vehicle includes a multi phase machine (e.g., 106). In some examples, the multi-phase machine is a six-phase machine with a first set of phases (e.g., 107A-107C) and a second set of phases (e.g., 107D-107F) each being a three-phase system.
[0036] At block 604, in response to the controller determining that the direction of energy flow is from the electric grid to the electric vehicle (e.g., the controller receives a first request for energy flow from the electric grid to the electric vehicle), the controller operates the first set of phases in the multi-phase machine through a first inverter (e.g., 108), where the first set of phases in the multi-phase machine is operated at a grid frequency of the electric grid. In some embodiments, operating the first set of phases in the multi-phase machine through the first inverter includes closing a first set of switches (e.g., 122) to connect the first set of phases in the multi-phase machine to the first inverter.
[0037] At block 606, in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, the controller switches the first set of phases in the multi-phase machine to the electric grid. In some embodiments, when the first set of phases in the multi-phase machine is operated at the grid frequency of the electric grid, the controller isolates the first set of phases in the multi phase machine from the first inverter by opening the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter. In certain embodiments, connecting the first set of phases in the multi-phase machine to the electric grid includes closing a second set of switches (e.g., 124) to connect the first set of phases in the multi-phase machine to the electric grid.
[0038] At block 608, in response to switching the first set of phases in the multi phase machine to the electric grid, the controller operates the second set of phases in the multi-phase machine through a second inverter (e.g., 110), where the second set of phases in the multi-phase machine generates energy via electrical coupling to the first set of phases in the multi-phase machine. At block 610, the controller provides the energy generated by the second set of phases in the multi-phase machine to charge an energy source (e.g., 116) of the electric vehicle.
[0039] Turning to block 612, in response to the controller determining that the direction of energy flow is from the electric vehicle to the electric grid (e.g., the controller receives a second request for energy flow from the electric vehicle to the electric grid), the controller operates the second set of phases in the multi-phase machine through a second inverter (e.g., 110), where the second set of phases in the multi-phase machine is operated at the grid frequency of the electric grid.
[0040] At block 614, in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, the controller switches the first set of phases in the multi-phase machine to the electric grid, where the first set of phases in the multi-phase machine generates energy via electrical coupling to the second set of phases in the multi-phase machine and the energy generated by the first set of phases in the multi-phase machine is then provided to the electric grid. In some embodiments, switching the first set of phases in the multi-phase machine to the electric grid includes opening a first set of switches (e.g., 122) to disconnect the first set of phases in the multi phase machine from a first inverter (e.g., 108) and closing a second set of switches (e.g., 124) to connect the first set of phases in the multi-phase machine to the electric grid.
[0041] This application is intended to cover any variations, uses, or adaptations of the present disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which the present disclosure pertains and which fall within the limits of the appended claims.
[0042] Furthermore, the connecting lines shown in the various figures contained herein are intended to represent functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements. The scope is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.”
[0043] Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B or C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.
[0044] Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic with the benefit of this disclosure in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. [0045] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Claims

CLAIMS What is claimed is:
1. A system, comprising: a multi-phase machine; and a controller coupled to the multi-phase machine, the controller configured to: receive a first request for energy flow from an electric grid to an electric vehicle; operate a first set of phases in the multi-phase machine through a first inverter, the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid; in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switch the first set of phases in the multi-phase machine to the electric grid; in response to switching the first set of phases in the multi-phase machine to the electric grid, operate a second set of phases in the multi-phase machine through a second inverter, the second set of phases in the multi -phase machine generating energy via electrical coupling to the first set of phases in the multi-phase machine; and provide the energy generated by the second set of phases in the multi -phase machine to charge an energy source of the electric vehicle.
2. The system of claim 1, further comprising a first set of switches and a second set of switches and the controller is further configured to: operate the first set of phases in the multi-phase machine through the first inverter by closing the first set of switches to connect the first set of phases in the multi-phase machine to the first inverter; in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, open the first set of switches to disconnect the first set of phases in the multi -phase machine from the first inverter; and connect the first set of phases in the multi-phase machine to the electric grid by closing the second set of switches to connect the first set of phases in the multi phase machine to the electric grid.
3. The system of claim 1, wherein the controller is further configured to: receive a second request for energy flow from the electric vehicle to the electric grid; operate the second set of phases in the multi -phase machine through the second inverter, the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid; and in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switch the first set of phases in the multi-phase machine to the electric grid, the first set of phases in the multi phase machine generating energy via electrical coupling to the second set of phases in the multi-phase machine, wherein the energy generated by the first set of phases in the multi-phase machine is supplied to the electric grid.
4. The system of claim 3, further comprising a first set of switches and a second set of switches and the controller is further configured to: connect the first set of phases in the multi-phase machine to the electric grid by opening the first set of switches to disconnect the first set of phases in the multi phase machine from the first inverter and closing the second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
5. The system of claim 1, wherein the multi-phase machine is a six-phase machine with each of the first set of phases and the second set of phases being a three- phase system.
6. A controller, comprising: a processor; and a memory including instructions that, when executed by the processor, cause the controller to: receive a first request for energy flow from an electric grid to an electric vehicle, the electric vehicle having a multi-phase machine; operate a first set of phases in the multi-phase machine through a first inverter, the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid; in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switch the first set of phases in the multi-phase machine to the electric grid; in response to switching the first set of phases in the multi-phase machine to the electric grid, operate a second set of phases in the multi-phase machine through a second inverter, the second set of phases in the multi-phase machine generating energy via electrical coupling to the first set of phases in the multi-phase machine; and provide the energy generated by the second set of phases in the multi -phase machine to charge an energy source of the electric vehicle.
7. The controller of claim 6, wherein the instructions, when executed by the processor, further cause the controller to: in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, isolate the first set of phases in the multi-phase machine from the first inverter.
8. The controller of claim 7, wherein the instructions, when executed by the processor, to cause the controller to operate the first set of phases in the multi-phase machine through the first inverter further cause the controller to close a first set of switches to connect the first set of phases in the multi -phase machine to the first inverter.
9. The controller of claim 8, wherein the instructions, when executed by the processor, to cause the controller to isolate the first set of phases in the multi-phase machine from the first inverter further cause the controller to open the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter.
10. The controller of claim 9, wherein the instructions, when executed by the processor, to cause the controller to connect the first set of phases in the multi-phase machine to the electric grid further cause the controller to close a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
11. The controller of claim 6, wherein the instructions, when executed by the processor, further cause the controller to: receive a second request for energy flow from the electric vehicle to the electric grid; operate the second set of phases in the multi -phase machine through the second inverter, the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid; and in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switch the first set of phases in the multi-phase machine to the electric grid, the first set of phases in the multi phase machine generating energy via electrical coupling to the second set of phases in the multi-phase machine, wherein the energy generated by the first set of phases in the multi-phase machine is supplied to the electric grid.
12. The controller of claim 11, wherein the instructions, when executed by the processor, to cause the controller to switch the first set of phases in the multi-phase machine to the electric grid further cause the controller to open a first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter and close a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
13. A method, compri sing : determining, by a controller, a direction of energy flow between an electric vehicle and an electric grid, the electric vehicle having a multi-phase machine; in response to determining that the direction of energy flow is from the electric grid to the electric vehicle, operating, by the controller, a first set of phases in the multi-phase machine through a first inverter, the first set of phases in the multi-phase machine being operated at a grid frequency of the electric grid; in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switching, by the controller, the first set of phases in the multi-phase machine to the electric grid; in response to switching the first set of phases in the multi-phase machine to the electric grid, operating, by the controller, a second set of phases in the multi-phase machine through a second inverter, the second set of phases in the multi-phase machine generating energy via electrical coupling to the first set of phases in the multi-phase machine; and providing, by the controller, the energy generated by the second set of phases in the multi-phase machine to charge an energy source of the electric vehicle.
14. The method of claim 13, further comprising: in response to the first set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, isolating, by the controller, the first set of phases in the multi-phase machine from the first inverter.
15. The method of claim 14, wherein operating the first set of phases in the multi-phase machine through the first inverter includes closing a first set of switches to connect the first set of phases in the multi-phase machine to the first inverter.
16. The method of claim 15, wherein isolating the first set of phases in the multi-phase machine from the first inverter includes opening the first set of switches to disconnect the first set of phases in the multi-phase machine from the first inverter.
17. The method of claim 16, wherein connecting the first set of phases in the multi-phase machine to the electric grid includes closing a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
18. The method of claim 13, further comprising: in response to determining that the direction of energy flow is from the electric vehicle to the electric grid, operating, by the controller, the second set of phases in the multi-phase machine through the second inverter, the second set of phases in the multi phase machine being operated at the grid frequency of the electric grid; and in response to the second set of phases in the multi-phase machine being operated at the grid frequency of the electric grid, switching, by the controller, the first set of phases in the first multi-phase machine to the electric grid, the first set of phases in the multi phase machine generating energy via electrical coupling to the second set of phases in the multi-phase machine, wherein the energy generated by the first set of phases in the multi phase machine is provided to the electric grid.
19. The method of claim 18, wherein switching the first set of phases in the multi-phase machine to the electric grid includes opening a first set of switches to disconnect the first set of phases in the multi -phase machine from the first inverter and closing a second set of switches to connect the first set of phases in the multi-phase machine to the electric grid.
20. The method of claim 13, wherein the multi-phase machine is a six-phase machine with each of the first set of phases and the second set of phases being a three- phase system.
PCT/US2021/040114 2020-07-14 2021-07-01 Bidirectional electric vehicle charging with multi-phase machines Ceased WO2022015519A1 (en)

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CN202180048986.8A CN115803219A (en) 2020-07-14 2021-07-01 Bidirectional Electric Vehicle Charging Using Multiphase Motors
EP21841631.1A EP4182182A4 (en) 2020-07-14 2021-07-01 BIDIRECTIONAL ELECTRIC VEHICLE CHARGING WITH MULTI-PHASE MACHINES
US18/792,221 US20240391336A1 (en) 2020-07-14 2024-08-01 Bidirectional electric vehicle charging with multi-phase machines

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