Vehicle power sharing and grid connection system for electric motors and drives

Abstract

A power sharing system for electric motors and drives shares power between multiple power sources. Multiple motor drives share power between multiple energy sources, without the need for a DC to DC converter. A motor drive adapts the DC voltage range of the power source to either AC voltage or a different DC voltage range to operate one or more electric motors. Either a capacitor bank or a battery is directly connected to a motor drive's DC input. Two separate DC inputs exist, each able to operate at its own voltage and both feeding the same motor through separate motor drives, to allow batteries to be operated at one voltage level while capacitors are operated at another. The motor drives inherently cause power to flow between the motor and either power source, regardless of the relative voltages of the two sources, provided that each source is at a sufficient voltage to power the motor independently.

Claims

1. A power sharing system comprising: a battery pack for supplying electric power to an electric motor; an ultra-capacitor bank for supplying electric power in parallel with said battery pack to said electric motor; said controller connected to a separate input of said electric motor; each said input at its own voltage to allow said battery pack to be operated at one voltage level while said ultra-capacitor bank is operated at another voltage level; a controller containing basic operational parameters and providing an interface to said inputs, whereby said controller matches varying torque demands of said electric motor with available power from said battery pack and ultra-capacitor whereby said ultra-capacitor has most of the power capacity of said power sharing system for providing short bursts of power when required by said motor; and said power sharing system operating without use of a DC to DC converter.

2. Apparatus for sharing electric power between multiple energy sources in a vehicle or machine comprising: an AC electric motor; a first motor drive inverter for delivering a first AC current to AC motor wires of said electric motor; a first source of DC power for delivering a DC voltage to said first motor drive inverter; a second motor drive inverter for delivering AC current to said AC motor wires of said electric motor; a second source of DC electric power for delivering a DC voltage to said second motor drive inverter, and a controller connected to both of said first and second motor drive inverters containing basic operational parameters and providing an interface to the vehicle or machine, whereby said controller distributes power between said first and second sources of DC according to varying torque demands of said electric motor, and whereby said second source of DC has most of the power capacity of said power sharing system for providing short bursts of power when required by said motor.

3. The apparatus of claim 2 wherein said second motor drive inverter delivers AC current to said AC motor wires through inductors or a low pass filter to facilitate filtering of unwanted switching transients between the two inverters.

4. The apparatus of claim 2 in which said first source of DC electric power is a battery pack.

5. The apparatus of claim 2 in which said second source of DC electric power is an ultra-capacitor bank and only said second motor drive inverter is bi-directional for providing regeneration during braking.

6. The apparatus of claim 4 in which said second source of DC electric power is an ultra-capacitor bank, whereby said ultra-capacitor bank meets temporary higher energy demands of said electric motor.

7. The apparatus of claim 6 having a device for sensing the phase of the AC power coming from one of said inverters to generate a simulated encoder signal for the second inverter.

8. The apparatus of claim 6 in which said apparatus provides drive in a vehicle whereby said second source of DC electric power is utilized for acceleration of said vehicle and regeneration of said battery pack.

9. The apparatus of claim 2 wherein said apparatus operates without the use of a DC to DC converter.

10. Apparatus in a vehicle or machine for sharing electric power between multiple energy sources comprising: a first power system comprising a first AC electric motor, a first motor drive inverter for delivering a first AC voltage to AC motor wires of said first electric motor and a first source of DC power for delivering a first DC voltage to said first motor drive inverter; at least one further power system comprising at least one further AC electric motor, at least one further motor drive inverter for delivering at least one further AC voltage to AC motor wires of said second electric motor and at least one further source of DC electric power for delivering at least one further DC voltage to said second motor drive inverter, and wherein said apparatus operates without the use of a DC to DC converter; said first and second AC electric motors being mechanically coupled together to operate on a common load; said first and second power systems operating at different DC voltage levels; and a controller connected to both of said first and second motor drive inverters to distribute power between said first and second sources of DC electric power by modulating torque demands of the two motor drive inverters, and wherein only said further motor drive inverter is bi-directional for providing regeneration during braking.

11. The apparatus of claim 10 in which said first source of DC power is a battery pack.

12. The apparatus of claim 10 in which said second source of DC power is an ultra-capacitor bank.

13. The apparatus of claim 11 in which said second source of DC power is an ultra-capacitor bank.

14. The apparatus of claim 13 in which said controller and associated data bus connected to both said inverters contain basic operational parameters providing an interface to a vehicle or machine in which said apparatus is incorporated.

15. The apparatus of claim 14 in which said apparatus provides drive in a vehicle whereby said second power system is utilized for acceleration of said vehicle and for regeneration of said ultra-capacitor pack in said second power system during vehicle braking periods.

16. The apparatus of claim 10 wherein said first and send AC electric motors being mechanically coupled together to operate on a common load are instead coupled mechanically through a gear-set and an electrically controlled clutch for more efficient operation.

17. Apparatus for sharing power from multiple DC electric power sources in a series or parallel hybrid vehicle comprising: an AC electric propulsion drive motor; a first battery pack connected to said AC motor through an inverter; at least one further battery pack connected to said AC motor through at least one further inverter and an AC line filter; an internal combustion engine powering a DC generator; a third inverter accepting DC power from said DC generator and connected to said AC motor through an AC line filter; an ultra-capacitor bank connected to said AC motor through a bi-directional inverter and an AC line filter; and a controller responsive to vehicle power demands sharing the power load of said AC motor among all four DC input power sources.

18. The apparatus of claim 17 wherein said apparatus operates without the use of a DC to DC converter.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in drawings, in which:

(2) FIG. 1 is a block diagram of a Prior Art power system for a vehicle with an electric motor which utilizes a DC to DC converter;

(3) FIG. 2 is a block diagram of one embodiment of the present invention, which couples two drives to one electric motor, using two electric power sources;

(4) FIG. 2A shows a Prior Art block diagram of a typical AC mains connected inverter.

(5) FIG. 2B shows a block diagram of a typical Prior Art AC motor drive inverter.

(6) FIG. 2C shows an AC motor drive inverter coupled to the AC mains, using the invention as a sensing interface.

(7) FIG. 3 is a block diagram of an alternate embodiment of the present invention, which couples two electric motors together, also using two electric power sources.

(8) FIG. 4 is a block representing the controller with its set of inputs.

(9) FIG. 5 is perspective schematic view of a two motor embodiment with a gear-set and an electrically operated clutch coupling the two motors.

(10) FIG. 6 is a block diagram using a system of the type of the first embodiment of this invention as configured to operate with four separate DC voltage sources as found in a series hybrid vehicle.

DETAILED DESCRIPTION OF THE DRAWINGS

(11) The present invention has broad applications to many technical fields for a variety of articles. For illustrative purposes only, a preferred mode for carrying out the invention is described herein.

(12) FIG. 1 shows the major components of a typical Prior Art vehicle power drive system in which a DC to DC converter is used to couple an ultra-capacitor to a battery bank and motor drive. The Motor Drive Inverter 4 is used to convert DC power from the DC Bus 7 into AC power, which is carried on the AC Motor Wires 8 to the provide power to the Electric Motor 5. The Motor Drive Inverter 4 operates at a particular voltage V2, which is constrained by the operational voltage range of the Battery Pack 3. The DC to DC Converter 2 adapts the voltage range V1 of the Ultra-capacitor Bank 1 to the voltage range V2 of the Battery Pack 3. All electrical power to the Electric Motor 5 flows through the Motor Drive Inverter (4) from the DC Bus (7). The DC to DC Converter (2) determines the level of power sharing between the Ultra-capacitor Bank 1 and the Battery Pack 3 by modulating the current flow between the two. The DC to DC Converter 2 is a costly item which is not readily available off the shelf. In addition, power is lost due to conversion efficiency when it is moved between the Ultra-capacitor Bank 1 and the DC Bus 7. There is also a Controller 12 and an associated Data Bus 13 that is connected to the Motor Drive Inverter 4 that contains the basic operational parameters and provides an interface to the vehicle or machine using the motor drive system.

(13) FIG. 2 shows one possible embodiment of the proposed system, in which two power sources, a battery pack 3 and an ultra-capacitor bank 1, are coupled to one electric motor 5 via two motor drives without the need for a DC to DC converter. The Electric Motor 5 can now receive power from both the Battery Motor Drive Inverter 4 and the Capacitor Motor Drive Inverter 9. The Battery Motor Drive Inverter 4 drives the Electric Motor 5 with power from a storage element, such as the Battery Pack 3, via the DC Bus 7, operating at voltage V2. The Capacitor Motor Drive Inverter 9 drives the Electric Motor 5 with power from another storage element, such as the Ultra-capacitor Bank 1, via the Ultra-capacitor Voltage Bus 6, operating at voltage V1. The distribution of power between the two storage elements 1 and 3 is controlled by controlling the torque commands to the two Motor Drive Inverters 4 and 9 where Battery Motor Driver Inverter 4 controls power exchange of the battery pack 3 and where Capacitor Motor Drive Inverter 9 controls power exchange of Capacitor Bank 1. Additionally, depending on the designs of the two Motor Drive Inverters 4 and 9, it may be necessary to couple the two Inverters 4 and 9 together on the AC side via a Three Phase Inductor 10. Although the two inverters are synchronized as to frequency and phase, inductor 10 is used to prevent switching transients from one inverter to interfere with the other. In fact, three phase double stage filters such as the FVDT series from MEMO S.L. of Malaga, Spain or custom or standard power line inductors and filters from Scaffner EMC Inc. of Edison N.J. can also be used for this purpose. There is also a Controller 12 and an associated Data Bus 13, that is connected to the Motor Drive Inverter 4 and Capacitor Drive Inverter 9 that contains the basic operational parameters and provides an interface to the vehicle or machine using the invention. The invention also utilizes a device which senses the phase of the AC power coming from one of the Motor Drive Inverters 4 or 9 and generates a simulated encoder signal for the second inverter.

(14) FIG. 2A shows a standard grid connected Motor Drive Inverter that can be purchased commercially. This device is connected to a typical AC Mains 41 and is comprised of a Logic Control and Power Stage 44 and uses a Grid Sensing Circuit 42 with and Input Filter 43 with and Output Filter 45 on its output before powering the AC Electric Motor 46 load. It utilizes an Encoder 47 to monitor the position of the electric motor. The combined elements work together to provide control and operation of an AC motor in either speed on torque mode whereby the motor is providing motive force to keep a vehicle moving down the road. Typical Motor Drive Inverters do not work when the grid is not present thus back driving the grid is not possible. However through the use of the Encoder Emulator 46 as described below, the same inverter can be used to back feed the grid and provide power to an electric motor that provides motive power to a vehicle.

(15) FIG. 2B shows a standard AC motor drive that uses a DC source for power. It uses all the components used in the grid connected inverter shown in FIG. 2A, but omits the Grid Sensing Circuit 42 since no grid is present, but powers the AC motor in the same manner.

(16) FIG. 2C shows the use of the Encoder Emulator 46 in the invention. The output of the inverter can be connected to an Electric Motor 46, the AC Mains or Other Inverter 51 through an Inductor 50 for power conditioning. In order to utilize the same Motor Drive Inverter hardware, the encoder input point is the same for the standard Encoder 47 or the Encoder Emulator 46.

(17) FIG. 4 shows a controller 12 block with some vehicle inputs and power source input parameters shown. The vehicle inputs are indicative of the current operating state of the vehicle such as vehicle speed, accelerator pedal position, brake pedal position, transmission gear (if applicable). The power source parameters include battery pack 3 voltage and state of charge, capacitor bank 1 voltage and state of charge (for diagnostic comparison), and motor 5 speed.

(18) It is noted that inverter 9 which powers motor 5 from the ultra-capacitor bank 1 must also be a bi-directional type which recharges capacitor bank 1 during braking when motor 5 is used as an alternator to implement regenerative braking. This takes AC power generated by motor 5 and converts it to DC power to charge the capacitor bank during the braking phase. A good example of the general type of bi-directional inverter 9 is the MPS-100™ series bi-directional inverters from Dynapower Corporation of South Burlington, Vt. 05403.

(19) FIG. 3 shows another possible embodiment of the proposed system, in which two power sources, a battery pack 3 and an Ultra-capacitor bank 1, are coupled to the mechanical system via two motor drives and two motors, without the need for a DC to DC converter. In this case, two independent motor drive systems are operating on a common load via some form of mechanical coupling. In the first system, power is exchanged between the Battery Pack 3 and the Electric Motor 5 via the Battery Motor Drive Inverter 4. In the second system, power is exchanged between the Ultra-capacitor Bank 1 and the Electric Motor 11 via the Capacitor Motor Drive Inverter 9. The two systems are able to operate at different DC voltage levels V1 and V2. Power is distributed between the two storage elements 1 and 3, such as Ultra-capacitor Bank 1 and Battery Pack 3, by modulation of the torque commands to the two Motor Drive Inverters 4 and 9, where Battery Motor Drive Inverter 4 controls power exchange of the battery pack 3 and where Capacitor Motor Driver Inverter 9 controls power exchange of the Ultra-capacitor Bank 1. The power from the two Electric Motors 5 and 11 is combined by a Mechanical Coupling 14, which could be a common shaft, a flexible coupling, a gear set, or one or more clutches to minimize windage losses, in cases where one of the motors is shut down as, for example, when the ultra-capacitor bank is depleted. There is also a Controller 12 and an associated Data Bus 13 that is connected to the Motor Drive Inverter 4 and Capacitor Drive Inverter 9 that contains the basic operational parameters and provides an interface to the vehicle or machine using the invention.

(20) It is noted that in this second embodiment electric motor 11 need not be the same type as motor 5. In fact, motor 11 could be a brushless DC motor while motor 5 is a three-phase AC motor. In such a case, capacitor motor drive inverter 9 would be replaced by a regenerative (bi-directional) DC motor drive. Note that the use of two separate motors permits motor 11 to be physically small since it can be designed as an intermittent duty motor with lower heat dissipation demands.

(21) FIG. 5 shows an alternative to the direct coupling of motors 5 and 11. Here, the coupling is achieved via gear-set 16 and electrically operated clutch 17. Note that the step-up in rotational speed from motor 5 to motor 11 is advantageous to generating higher voltages to quickly charge capacitor bank 1 while clutch 17 isolates gear-set 16 and motor 11 from the driving motor 5 when capacitor bank 1 is depleted.

(22) FIG. 6 shows a system 20 depicting the use of a single drive motor system of this invention sharing power from four DC power sources to drive a single three-phase motor 21. The application is a series hybrid vehicle. The battery packs 22 and 24 are partitioned to permit swapping out when depleted. Internal combustion engine (ICE) 27 drives a DC generator (or alternator with output rectifiers) 28. The fourth DC power source is ultra-capacitor bank 31 which stores energy recaptured during braking. Each of the four DC power sources (22,24,28, and 31) has it's associated inverter (23, 25, 29, and 32 respectively) feeding a common three-phase bus with filters 26, 30, and 33 isolating any switching transients among the inverters. Note that inverter 32 is bi-directional to permit charging of capacitor bank 31 during braking. Controller 35 fields all system sensor inputs 36 and controls all inverters, ICE 27 and DC generator 28 through output control data bus 37.

(23) In the foregoing description, certain terms and visual depictions are used to illustrate the preferred embodiment. However, no unnecessary limitations are to be construed by the terms used or illustrations depicted, beyond what is shown in the prior art, since the terms and illustrations are exemplary only, and are not meant to limit the scope of the present invention.

(24) It is further known that other modifications may be made to the present invention, without departing the scope of the invention, as noted in the appended Claims.