METHOD AND A MASTER CONTROL UNIT FOR CONTROLLING AN ELECTRICAL SYSTEM OF AN ELECTRIC VEHICLE

Abstract

A method for controlling an electrical system of an electric vehicle. The electrical system comprises a vehicle network and an external network having one or more external loads and connectable to an on-board network. The vehicle network comprises a converter unit adapted for connecting a traction voltage network and an on-board network having a battery unit and one or more internal loads and connected to the converter unit; and a switching unit adapted for controlling power output to the external network by connecting and disconnecting the on-board network and external network. The method comprises the steps of determining at least one current information of the electrical system and at least one safety current value; and controlling the switching unit to control the power output from the on-board network to the external network depending on the at least one current information and the at least one safety current value.

Claims

1. A method for controlling an electrical system of an electric vehicle, in particular an electric heavy-duty vehicle, the electrical system comprising: a vehicle network, the vehicle network comprising a converter unit being adapted for connecting a traction voltage network and an on-board network; the on-board network having a battery unit and one or more internal loads, wherein the on-board network is connected to the converter unit; a switching unit that is adapted for controlling a power output to the external network by connecting and disconnecting the on-board network and an external network; the external network having one or more external loads, wherein the external network is connectable to the on-board network via the switching unit; and the method comprising the steps of: determining at least one current information of the electrical system; determining at least one safety current value; and controlling the switching unit to control the power output from the on-board network to the external network depending on the determined at least one current information of the electrical system and the determined at least one safety current value.

2. A method according to previous claim 1, further comprising: wherein the vehicle network comprises a traction voltage network having one or more traction electric motors for driving the electric vehicle and/or an electric storage system and/or loads; and/or wherein the at least one safety current value is at least one of the following: a current protection value; and/or a limitation value; and/or wherein the at least one current information of the electrical system is at least one of the following: a status information of the converter unit, the status information of the converter unit comprising at least one of the following: an operation status of the converter unit; and/or an actual converter output current; and/or a maximum converter current capacity value; and/or a battery current value of the battery of the on-board network; and/or an external load current consumption value of the external network.

3. A method according to claim 1, wherein the step of controlling the power output from the on-board network to the external network comprises: closing the switching unit for connecting the on-board network with the external network; and/or opening the switching unit for disconnecting the on-board network from the external network; and/or discrete or continuous adjustment of the switching unit for discrete or continuous adjustment of the output power.

4. A method according to claim 1, wherein the one or more internal loads are one or more non-critical internal loads and/or one or more critical internal loads; the method further comprising: controlling the one or more non-critical internal loads depending on the determined at least one current information of the electrical system, wherein the step of controlling the one or more non-critical internal loads comprises: connecting and/or disconnecting the one or more non-critical internal loads from the on-board network; and/or discrete or continuous adjustment of the one or more non-critical internal loads.

5. A method according to claim 1, wherein the switching unit is closed if the determined operation status of the converter unit signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network and under charge and the determined actual converter output current minus the determined battery current value is below a threshold of the determined maximum converter current capacity value; and/or the switching unit is opened if the determined operation status of the converter unit does not signal readiness for operation; and/or the switching unit is controlled discretely or continuously to discretely or continuously control the output power if the determined operation status of the converter unit signals partial readiness for operation and/or the determined battery current value signals that the battery is not connected to the on-board network and/or not under charge; or the determined operation status of the converter unit signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network and under charge and the determined actual converter output current minus the determined battery current value is above the threshold of the determined maximum converter current capacity value.

6. A method according to claim 1, further comprising: wherein the step of determining at least one safety current value comprises: defining a minimum and/or maximum safety current value; and/or determining the at least one safety current value as maximum safety current value if the determined operation status of the converter unit signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network and under charge and the determined actual converter output current minus the determined battery current value is below the threshold of the determined maximum converter current capacity value; and/or determining the at least one safety current value as minimum safety current value if the determined operation status of the converter unit does not signal readiness for operation; and/or the determined battery current value signals that the battery is connected to the on-board network and/or under discharge; and/or determining the at least one safety current value as a minimum of the sum of the determined maximum converter current capacity value minus the determined actual converter output current plus the determined battery current value plus the external load current consumption value and the maximum safety current value  if the determined operation status of the converter unit signals partial readiness for operation and/or the determined battery current value signals that the battery is not connected to the on-board network and/or under discharge;  or the determined operation status of the converter unit signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network and under charge and the determined actual converter output current minus the determined battery current value is above the determined at least one safety current value.

7. A master control unit for controlling an electrical system of an electric vehicle, in particular an electric heavy-duty vehicle, wherein the master control unit is configured to perform the steps of the method according to claim 1.

8. A computer program comprising program code means for performing the steps of the method according to claim 1 when said program is run on the master control unit according to previous claim 7.

9. A computer readable medium carrying a computer program comprising program code means for performing the steps of the method according to claim 1 when said program product is run on the master control unit according to previous claim 7.

10. An electrical system of an electric vehicle, in particular an electric heavy-duty vehicle, comprising a vehicle network, the vehicle network comprising a converter unit being adapted for connecting a traction voltage network and an on-board network; an on-board network having a battery unit and one or more internal loads, wherein the on-board network is connected to the converter unit; an external network having one or more external loads, wherein the external network is connectable to the on-board network via a switching unit; the vehicle network comprises the switching unit for controlling a power output to the external network, wherein the switching unit is adapted for connecting and disconnecting the on-board network and an external network depending on at least one determined current information of the electrical system and a determined at least one safety current value, and a master control unit according to claim 7 that is being signal-coupled with the electrical system and adapted for controlling the electrical system, in particular the switching unit.

11. An electrical system according to claim 10, wherein the vehicle network comprises the traction voltage network having one or more traction electric motors for driving the electric vehicle and/or an electric storage system and/or loads; and/or wherein the switching unit is an electrical switch, in particular a relay, and/or a transistor, in particular a MOSFET.

12. An electrical system according to claim 10, wherein the master control unit is signal-coupled with the switching unit and/or the converter unit and/or the on-board network.

13. An electrical system according to claim 10, comprising a vehicle control unit adapted for controlling one or more internal loads, in particular one or more non-critical internal loads, of the on-board network, wherein preferably the vehicle control unit is configured to perform the steps of the method according to claim 1.

14. An electrical system according to previous claim 13, wherein the vehicle control unit is signal-coupled with the converter unit and/or the on-board network and/or the one or more internal loads, in particular one or more non-critical internal loads.

15. An electric vehicle, in particular an electric heavy-duty vehicle, comprising an electrical system according to claim 10.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0044] With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples.

[0045] In the drawings:

[0046] FIG. 1 is a side view of an electric heavy-duty vehicle comprising an electric system;

[0047] FIG. 2 is a detailed view of an electric system of the electric heavy-duty vehicle of FIG. 1;

[0048] FIG. 3 is a first embodiment of a schematic flow diagram of a method for controlling an electrical system of FIG. 2;

[0049] FIG. 4 is a second embodiment of a schematic flow diagram of a method for controlling an electrical system of FIG. 2;

[0050] FIG. 5 is a first use case (partial readiness for operation of the converter unit) of a schematically illustration when a severe issue occurs with an associated reaction of the electric system; and

[0051] FIG. 6 is a second use case (disconnected battery unit) of a schematically illustration when a severe issue occurs with an associated reaction of the electric system.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

[0052] FIG. 1 represents an electric heavy-duty vehicle 1 In the example, the electric heavy-duty vehicle 1 is a garbage truck. The electric heavy-duty vehicle 1 comprises an electrical system 10. Such an electrical system 10 comprises a vehicle network 20 and an external network 400.

[0053] FIG. 2 is a detailed view of an electric system of the electric heavy-duty vehicle of FIG. 1. The vehicle network 20 comprises a converter unit 300 and an on-board network 200. The on-board network 200 comprises a battery unit 201 and one or more internal loads 202a, 202b. The on-board network 200 and the converter unit 300 are connected. The converter unit 300 is adapted for connecting a traction voltage network 100 and an on-board network 200. The traction voltage network 100 comprises electric motors 101, an electric storage system 102 and traction loads 103. Further, the vehicle network 20 comprises a switching unit 600. The switching unit 600 is an electrical switch, in particular a relay, and/or a transistor, in particular a MOSFET.

[0054] By means of the switching unit 600 a power output to the external network 400 can be controlled. For this purpose, the switching unit 600 is adapted for connecting and disconnecting the on-board network 200 and an external network 400. In fact, the switching unit 600 connects and disconnects the external network 400 from the on-board network 200 depending on at least one determined current information of the electrical system 10 and a determined at least one safety current value. Such an external network 400 may have one or more external loads 401.

[0055] Further, the electric system 10 comprises a master control unit 500. The master control unit 500 is signal-coupled with the electrical system 10, in particular the switching unit 600, the converter unit 300, and the on-board network 200. The master control unit 500 is adapted for controlling an electrical system 10 of an electric heavy-duty vehicle 1, in particular its switching unit 600.

[0056] Additionally, but not compulsory, the electrical system 10 may comprise a vehicle control unit 700. The vehicle control unit 700 is signal-coupled with the converter unit 300, the on-board network 200, and one non-critical internal load 202a. The vehicle control unit 700 is adapted for controlling one or more internal loads 202, in particular one or more non-critical internal loads 202a, of the on-board network 200.

[0057] Both, the master control unit 500 and the vehicle control unit 700 are configured to perform the steps of a method for controlling an electrical system 10 of the electric heavy-duty vehicle 1.

[0058] FIG. 3 is a first embodiment of a schematic flow diagram of the method for controlling an electrical system of FIG. 2. The method comprises three steps.

[0059] Firstly, the method comprises the step of determining S1 at least one current information of the electrical system 10. The at least one current information of the electrical system 10 is a status information of the converter unit and/or a battery current value of the battery of the on-board network 200 and/or an external load current consumption value of the external network 400. Preferably, the status information of the converter unit 300 is at least one of the following: an operation status of the converter unit 300; an actual converter output current; and/or a maximum converter current capacity value.

[0060] Secondly, the method comprises the step of determining S2 at least one safety current value. The at least one safety current value is a current protection value and/or a limitation value.

[0061] Thirdly, the method comprises the step of controlling S3 the switching unit 600 to control the power output from the on-board network 200 to the external network 300 depending on the determined at least one current information of the electrical system 10 and the determined at least one safety current value. The step of controlling S3 the power output from the on-board network 200 to the external network 300 comprises closing the switching unit 600 for connecting the on-board network 200 with the external network 400. Additionally or alternatively, the step of controlling S3 the power output from the on-board network 200 to the external network 300 comprises opening the switching unit 600 for disconnecting the on-board network 200 from the external network 400. Also, a discrete or continuous adjustment of the switching unit 600 for discrete or continuous adjustment of the output power may be preferred.

[0062] The switching unit 600 is closed if the determined operation status of the converter unit 300 signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network 200 and under charge and the determined actual converter output current minus the determined battery current value is below a threshold of the determined maximum converter current capacity value. The switching unit 600 is opened if the determined operation status of the converter unit 300 does not signal readiness for operation.

[0063] The switching unit 600 is controlled discretely or continuously to discretely or continuously control the output power if the determined operation status of the converter unit 300 signals partial readiness for operation and/or the determined battery current value signals that the battery is not connected to the on-board network 200 and/or not under charge. Alternatively, the switching unit 600 is controlled discretely or continuously to discretely or continuously control the output power if the determined operation status of the converter unit 300 signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network 200 and under charge and the determined actual converter output current minus the determined battery current value is above the threshold of the determined maximum converter current capacity value.

[0064] FIG. 4 is a second embodiment of a schematic flow diagram of the method for controlling an electrical system of FIG. 2. The method comprises four steps. The second embodiment of the method schematically shown in FIG. 4 is based on the first embodiment of the method schematically shown in FIG. 3. The second embodiment of the method additionally comprises the step of controlling S4 the one or more non-critical internal loads 202a depending on the determined at least one current information of the electrical system. Preferably, the step of controlling S4 the one or more non-critical internal loads 202a comprises a sub-step of connecting and/or disconnecting the one or more non-critical internal loads 202a from the on-board network 200. Additionally or alternatively, the step of controlling S4 the one or more non-critical internal loads 202a comprises a sub-step of discrete or continuous adjustment of the one or more non-critical internal loads 202a.

[0065] In the second preferred embodiment shown in FIG. 4 the step of determining S2 at least one safety current value may comprise at least one of the four following sub-steps: A first sub-step is defining S20 a minimum and/or maximum safety current value. Alternatively or additionally, the second and third sub-steps are determining the at least one safety current value as maximum safety current value S21 and/or determining the at least one safety current value as minimum safety current value S22. Finally, the fourth sub-step is determining the at least one safety current value as a minimum S23 of the sum of the determined maximum converter current capacity value minus the determined actual converter output current plus the determined battery current value plus the external load current consumption value and the maximum safety current value.

[0066] The at least one safety current value is determined as maximum safety current value S21 if the determined operation status of the converter unit 300 signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network 200 and under charge and the determined actual converter output current minus the determined battery current value is below the threshold of the determined maximum converter current capacity value. The at least one safety current value is determined as minimum safety current value S22 if the determined operation status of the converter unit 300 does not signal readiness for operation; and/or the determined battery current value signals that the battery is connected to the on-board network 200 and/or under discharge.

[0067] The at least one safety current value is determined as minimum safety current value S23 of the sum of the determined maximum converter current capacity value minus the determined actual converter output current plus the determined battery current value plus the external load current consumption value and the maximum safety current value if the determined operation status of the converter unit 300 signals partial readiness for operation and/or the determined battery current value signals that the battery is not connected to the on-board network 200 and/or under discharge. Alternatively, the at least one safety current value is determined as minimum safety current value S23 of the sum of the determined maximum converter current capacity value minus the determined actual converter output current plus the determined battery current value plus the external load current consumption value and the maximum safety current value if the determined operation status of the converter unit 300 signals full readiness for operation, and the determined battery current value signals that the battery is connected to the on-board network 200 and under charge and the determined actual converter output current minus the determined battery current value is above the determined at least one safety current value.

[0068] So generally speaking, if a severe issue is detected—as described above—on a vehicle network leading to a stop of operation of the converter unit 300, the power output from the on-board network 200 to the external network 300 is controlled by opening the switching unit 600, to limit as much as possible the current consumption on the on-board network (that will be supplied from batteries). In parallel, other non-safety high power loads—i.e. for example non-critical internal loads 202a—can be cut-off. This can be directly controlled from a vehicle control unit 700. This in order to ensure a safe stop of the electric vehicle 1.

[0069] FIGS. 5 and 6 schematically illustrate two use cases when a severe issues M occurs with an associated reaction of the electric system 10, respectively of the method for controlling the electrical system 10 of the electric vehicle 1.

[0070] FIG. 5 refers to a first use case, schematically illustrates the maximum converter current capacity value “A”, the actual converter output current “B”, the battery current value of the battery of the on-board network “C”, the safety current value “D”, the external load current consumption value of the external network “E”, and the non-critical internal load current “F” over time if a severe issue M is detected as described above. In case of the first use case, the severe issue detected M is a malfunctioning converter unit 300 that is derated. With regard to the first use case, to control the electric vehicle 1, the at least one safety current value is determined as minimum safety current value S22 as the determined operation status of the converter unit 300 signals its non-readiness for operation.

[0071] FIG. 6 refers to a second use case, schematically illustrates the maximum converter current capacity value “A”, the actual converter output current “B”, the battery current value of the battery of the on-board network “F”, the safety current value “D”, the external load current consumption value of the external network “E”, and a vehicle load current (without external loads) “C” over time if a severe issue M is detected as described above. In case of the second use case, the severe issue detected M is a detected low voltage battery open circuit in the on-board network 200. With regard to the second use case, to control the electric vehicle 1, the at least one safety current value is determined as minimum of the sum of the determined maximum converter current capacity value minus the determined actual converter output current plus the determined battery current value plus the external load current consumption value and the maximum safety current value as the determined battery current value signals that the battery is not connected to the on-board network 200. Further, at some time, the switching unit is controlled S3 in order to control the power output from the on-board network to the external network as the consumption value of the external network “E” would otherwise exceed the determined safety current value “D”.

REFERENCE SIGNS

[0072] 1 electric vehicle/electric heavy-duty vehicle [0073] 10 electrical system [0074] 20 vehicle network [0075] 100 traction voltage network [0076] 101 electric motors [0077] 102 electric storage system [0078] 103 traction loads [0079] 200 on-board network [0080] 201 battery unit [0081] 202a, 202b (non-critical and critical) internal loads [0082] 300 converter unit [0083] 400 external network [0084] 401 external loads [0085] 500 master control unit [0086] 600 switching unit [0087] 700 electric vehicle control unit [0088] S1 determining at least one current information of the electrical system [0089] S2 determining at least one safety current value [0090] S3 controlling the switching unit to control the power output from the on-board network to the external network [0091] S4 controlling the one or more non-critical internal loads