REDUNDANT POWER DISTRIBUTION CIRCUITS FOR ELECTRIC VEHICLES
20260008384 ยท 2026-01-08
Assignee
Inventors
Cpc classification
H02J1/12
ELECTRICITY
H02M1/0067
ELECTRICITY
B64D2221/00
PERFORMING OPERATIONS; TRANSPORTING
B64D35/02
PERFORMING OPERATIONS; TRANSPORTING
B64U50/19
PERFORMING OPERATIONS; TRANSPORTING
B60L58/19
PERFORMING OPERATIONS; TRANSPORTING
H02J7/575
ELECTRICITY
H01M10/482
ELECTRICITY
H02J7/90
ELECTRICITY
B60W10/26
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60L58/19
PERFORMING OPERATIONS; TRANSPORTING
B60W10/26
PERFORMING OPERATIONS; TRANSPORTING
B64D35/02
PERFORMING OPERATIONS; TRANSPORTING
G01R19/165
PHYSICS
H01M10/48
ELECTRICITY
H02J1/12
ELECTRICITY
H02J7/00
ELECTRICITY
Abstract
An electrically powered vehicle may include a DC bus and a plurality of batteries, each coupled in parallel to the DC bus. At least one switch is coupled in series between at least one battery of the plurality of batteries and the DC bus and a plurality of inverter circuits may each be coupled in parallel to the DC bus. A plurality of motors may each be coupled to a respective inverter circuit of the plurality of inverter circuits. In various embodiments, the electrically powered vehicle may further include a plurality of switches, each switch coupled in series between a respective battery of the plurality of batteries.
Claims
1. A system comprising: a controller configured to be coupled to a motor and configured to: monitor a voltage of a DC bus and a voltage of each battery of a plurality of batteries to detect an increase in the voltage of the DC bus indicative of occurrence of a regeneration event; in response to detecting the increase in the voltage of the DC bus indicative of the occurrence of the regeneration event, selectively engage one or more bypass switches to transfer power from the DC bus to one or more batteries of the plurality of batteries to charge only those batteries of the plurality of batteries that have a charge level below a particular threshold or to charge specific batteries of the plurality of batteries in a predetermined sequence; monitor each battery of the plurality of batteries for at least one fault condition during a regeneration event; and in response to detecting a fault condition of at least one battery of the plurality of batteries during the regeneration event, open at least one bypass switch of the one or more bypass switches to prevent flow of current from the DC bus to the plurality of batteries.
2. The system as recited in claim 1, wherein the selectively engaging the one or more bypass switches is to transfer power from the DC bus to the one or more batteries of the plurality of batteries to charge only those batteries of the plurality of batteries that have the charge level below the particular threshold.
3. The system as recited in claim 1, wherein the selectively engaging the one or more bypass switches is to transfer power from the DC bus to the one or more batteries of the plurality of batteries to charge the specific batteries of the plurality of batteries in the predetermined sequence.
4. The system as recited in claim 1, wherein the DC bus is coupled to an inverter circuit that is configured to generate an AC output used to drive the motor.
5. The system as recited in claim 1, wherein a diode of a plurality of diodes is respectively coupled in series between each battery of the plurality of batteries and the DC bus.
6. The system as recited in claim 5, wherein each bypass switch of the one or more bypass switches is configured to selectively bypass a corresponding diode of the plurality of diodes.
7. The system as recited in claim 1, wherein the controller is further configured to monitor the DC bus and each battery of the plurality of batteries to detect when the voltage of the DC bus decreases to a point that indicates an end of the regeneration event.
8. The system as recited in claim 7, wherein the controller is further configured to, responsive to the detecting when the voltage of the DC bus decreases to the point that indicates the end of the regeneration event, open the one or more bypass switches.
9. The system as recited in claim 1, wherein the detecting the increase in the voltage of the DC bus indicative of the occurrence of the regeneration event comprises determining that the voltage satisfies a threshold voltage.
10. The system as recited in claim 9, wherein the threshold voltage is based at least in part on a maximum voltage of any one of the plurality of batteries such that charge shuttling does not occur once the one or more bypass switches are engaged.
11. The system as recited in claim 1, wherein the selectively engaging the one or more bypass switches corresponds to engaging one bypass switch of a plurality of bypass switches at a time.
12. The system as recited in claim 1, wherein the selectively engaging the one or more bypass switches corresponds to engaging a subset of bypass switches at a time.
13. The system as recited in claim 1, wherein the selectively engaging the one or more bypass switches is based at least in part on detecting a low charge of at least one battery of the plurality of batteries.
14. The system as recited in claim 1, wherein the controller is coupled to a plurality of motors, the plurality of motors comprising the motor.
15. The system as recited in claim 14, wherein the controller is coupled to the plurality of motors via a plurality of inverter circuits, and each inverter circuit of the plurality of inverter circuits is configured to generate a respective AC output to drive a respective motor of the plurality of motors.
16. The system as recited in claim 15, wherein a plurality of bypass switches are coupled between the plurality of batteries and the DC bus, the plurality of bypass switches comprising the one or more bypass switches.
17. The system as recited in claim 16, wherein the motors are configured to drive components of an electric vehicle.
18. The system as recited in claim 17, wherein the electric vehicle is an electric aerial vehicle.
19. The system as recited in claim 18, wherein the components of the electric vehicle comprise at least one propeller.
20. The system as recited in claim 19, wherein each of the motors is coupled to a respective propeller.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
DETAILED DESCRIPTION
[0023] Techniques disclosed herein relate generally to electrical circuits for electrically powered vehicles. More specifically, techniques disclosed herein relate to power distribution circuits for electrically powered vehicles that include energy regeneration capability and redundant battery systems. Various inventive embodiments are described herein, including methods, processes, systems, devices, and the like.
[0024] In order to better appreciate the features and aspects of power distribution circuits for electrically powered vehicles according to the present disclosure, further context for the disclosure is provided in the following section by discussing one particular implementation of an electrically powered vehicle according to embodiments of the present disclosure. These embodiments are for example only and other embodiments can be employed in other electrically powered vehicles such as, but not limited to automobiles, trains, busses, motorcycles and scooters.
[0025]
[0026] Each battery is coupled in parallel to a common DC bus 110 that is coupled to a plurality of inverter circuits 115a-115c. Each inverter circuit 115a-115c is configured to generate a multiphase AC output that can be used to drive individual motors 120a-120c, which in one embodiment can be synchronous AC permanent magnet type motors. In some embodiments each inverter circuit 115a-115c is configured to generate a three-phase output that operates between 0 to 400 Volts AC at a frequency between 0 and 3 kHz, however one of skill in the art will appreciate that other numbers of phases, output voltages, output frequencies and types of electrical motors can be used without departing from the invention.
[0027] As further shown in
[0028] To enable batteries 105a-105c to receive regenerative power generated by motors 120a-120c, each circuit is equipped with a bypass switch 130a-130c that selectively bypasses each respective diode 125a-125c. More specifically, when engaged, each respective bypass switch 130a-130c enables power to be transferred from DC bus 110 to batteries 105a-105c so the batteries can be recharged with power generated by motors 120a-120c. In some embodiments bypass switches 130a-130c can be coupled to a controller 135 that monitors parameters of batteries 105a-105c and DC bus 110. Controller 135 can be configured to engage bypass switches 130a-130c to bypass respective diodes 125a-125c when DC bus 110 conditions (e.g., when a voltage level on the DC bus is higher than a voltage level of at least one of the batteries) indicate that a regenerative charging event is in process.
[0029] More specifically, in some embodiments, motors 120a-120c are configured to act as generators such that when the motors are rotated by external mechanical forces, the motors generate electricity that travels back through inverter circuits 115a-115c and to DC bus 110. When this occurs, the voltage on DC bus 110 can increase above the voltage of batteries 105a-105c and controller 135 can detect this increase and respond by closing one or more bypass switches 130a-130c allowing current to flow from the DC bus to one or more of the batteries. When the regenerative event ends, the voltage on DC bus 110 falls below the voltage of batteries 105a-105c and controller 135 responds by opening the bypass switches. In some embodiments controller 135 only enables regenerative charging of batteries 105a-105c when a voltage of DC bus 110 is above a threshold voltage, where the threshold voltage can be set based on a maximum voltage of any one of the batteries such that charge shuttling does not occur once the bypass switches are closed. In further embodiments, controller 135 can engage only one bypass switch at a time, or a subset of the bypass switches, to recharge individual batteries, which can be used in some embodiments for example, to top off any battery that has a relatively low charge.
[0030] In further embodiments, one or more bypass switches 130a-130c can be engaged by an external circuit, such as when an operator specifically engages a regenerative operation, such as descending in an airplane or depressing a brake pedal, for example. In other embodiments controller 130 can have logic circuitry that can selectively engage bypass switches 130a-130c to recharge only those batteries 105a-105c that have a charge level below a particular threshold or to charge specific batteries in a predetermined sequence to preserve their lifetime. One of ordinary skill in the art having the benefit of this disclosure, would recognize many variations, modifications, and alternative techniques of when and how to engage bypass switches 130a-130c.
[0031] In some embodiments bypass switches 130a-130c are electro-mechanical relay-type switches with metallic contacts that are engaged and disengaged by an electromagnet. In other embodiments bypass switches 130a-130c are solid-state and are made from silicon, gallium-nitride, silicon-carbide or other semiconductor material.
[0032] In some embodiments controller 135 can include fault monitoring and detection circuitry such that during a regenerative operation when one or more of bypass switches 130a-130c are closed if a fault is detected (e.g., a battery fails as a short) the bypass switch for that particular battery 105a-105c is opened, preventing the other batteries from discharging current to the failed battery. One of ordinary skill, with the benefit of this disclosure, would recognize many variations, modifications, and alternatives for using the bypass switches.
[0033] In some embodiments power distribution circuit 100 of
[0034] Batteries 105a-105c can be lead-acid, nickel-metal hydride, lithium-ion, lithium-ion polymer, alkaline or any other type of battery. Motors 120a-120c can be any type of AC motor including but not limited to, brush, brushless, induction, or synchronous. Inverters 115a-115c can by any type of analog or solid-state inverter circuit that converts DC power to AC power. For simplicity, various active and passive circuitry components are not shown in power distribution circuit 100.
[0035]
[0036] In one example controller 235 is configured to detect the failure of a battery 105a-105c that fails in a shorted condition. Controller 235 then commands breaker 230a-230c associated with that particular battery 105a-105c to open, protecting the battery from receiving current from the other batteries coupled to DC bus 110. During such a failure, controller 235 is configured to keep the other breakers 230a-230c closed so that power can continue to be provided to motors 120a-120c. In further embodiments controller 235 is configured to only open breakers 230a-230c that are necessary and to keep all other breakers closed so power can continue to be supplied to motors 120a-120c. This operating mode can be particularly useful for aerial vehicles where continuous uninterrupted operation of motors 120a-120c is an important safety consideration.
[0037] In some embodiments, breakers 230a-230c can be located proximate to batteries 105a-105c (as shown in
[0038] In some embodiments, breakers 230a-230c are electro-mechanical type switches with metallic contacts. In other embodiments breakers 230a-230c are solid-state and are made from silicon, gallium-nitride, silicon-carbide or other semiconductor material.
[0039]
[0040] Thus, each phase of motor 320 is driven by a respective interphase transformer 315a-315c that receives approximately 25 percent of its power from each of the four separate inverter/battery sets. When one battery 105a-105d or inverter 310a-310d fails, each phase of motor 330 will receive approximately 25 percent less power, but the motor will still operate. In some embodiments a master controller (not shown in
[0041] During a regenerative event when motor 330 is turned by external mechanical forces, the motor delivers power to each interphase transformer 315a-315c which then delivers power through the separate inverters 310a-310d back to batteries 105a-105d. Each battery 105a-105d is isolated from each other battery so if one battery fails power from the other batteries cannot flow to the failed battery. Essentially each battery and each AC signal are isolated so each operates as an isolated system. As appreciated by one of skill in the art having the benefit of this disclosure the number of batteries, the number of inverters and the number of interphase transformers are not limited to that shown in
[0042]
[0043] In this embodiment, when one battery 105a-105d fails, three phases of the twelve phases in motor 405 will not receive power so the motor will still operate, but at only approximately 75 percent of the power. In some embodiments the circuit can include a controller configured to control the other inverters (e.g., inverters that have not failed) of the plurality of inverters to continue operation of the motor with a reduced number of phases. The controller can also control the inverter coupled to the failed battery to isolate the failed battery from the circuit. Further, each battery 105a-105d and inverter 310a-310d are electrically isolated from one another, so if a battery fails in a shorted state, current from the other batteries will not flow to the failed battery. Essentially, each battery 105a-105d and inverter 310a-310d set is electrically isolated from each other battery and inverter set. Because of the isolation, charge shuttling between batteries 105a-105d is also not a concern.
[0044] During a regeneration event, rotational energy is applied to motor 405 which operates as a generator, delivering current to each battery 105a-105d through each respective inverter 310a-310d. In other embodiments motor 405 can have any number of phases and inverters 310a-310d can generate any number of phased outputs.
[0045]
[0046] Each DC/DC converter 505a-505d is configured to receive power from only its battery 105a-105d and deliver regulated power to DC bus 510 based on the load applied to the DC bus. More specifically, in some embodiments each DC/DC converter 505a-505d can be independently regulated and can use a voltage of DC bus 510 to control the amount of power the DC/DC converter extracts from its respective battery 105a-105d. In other embodiments a controller 525 can control each DC/DC converter 505a-505d and cycle them on and off as needed to regulate the power delivered to DC bus 510. More specifically, each DC/DC converter 505a-505d can run on a duty cycle where it is on for a given period of time and off for a given period of time.
[0047] In this embodiment, if a battery 105a-105d fails the DC/DC converter 505a-505d for that battery will not allow power to be transferred from DC bus 510 to the failed battery (e.g., if the battery fails in a shorted condition). In one example each DC/DC converter 505a-505d (or the controller 525) can monitor a voltage across each respective battery 105a-105d to detect a short or failure within the battery and in response discontinue the transfer of power from that battery to DC bus 510. In further embodiments, DC/DC converters 505a-505d can detect regenerative events and transfer power from DC bus 510 to batteries 105a-105d for recharging. In some embodiments the respective DC/DC converter 505a-505d can detect a regenerative event by monitoring a voltage potential on DC bus 510 as compared to the voltage available at the respective battery 105a-105d. In some embodiments a threshold voltage may be used to engage regenerative charging when a voltage on DC bus 510 exceeds the threshold voltage.
[0048] In some embodiments DC/DC converters 505a-505d can adjust the load sharing between each of the batteries 105a-105d to maintain each battery at a similar state of charge. In one embodiment each DC/DC converter 505a-505d monitors the respective battery 105a-105d voltage and a voltage on DC bus 510. If controller 525 senses a battery 105a-105d voltage that is relatively higher than the other battery voltages, the controller can command the respective DC/DC converter 505a-505d to draw more power from that battery to bring its charge state in line with the other batteries. In further embodiments each DC/DC converter 505a-505d can receive the same PWM (pulse-width modulation) signal from controller 525 that controls the transfer of power from each respective battery 105a-105d to DC bus 510. In some embodiments, the same PWM signal can automatically compensate for different charge levels in batteries 105a-105d by transferring more power from batteries having a relatively higher charge because of their higher voltage level and relatively less power from batteries having a relatively lower charge because of their lower voltage levels.
[0049] In some embodiments DC/DC converters 505a-505d can be placed proximate batteries 105a-105d while in other embodiments they can be placed proximate motors 520a-520c. In further embodiments DC bus 510 can be eliminated and each DC/DC converter 505a-505d can be coupled to a respective inverter 515a-515c and each respective inverter can be coupled to a respective motor 520a-520c as shown in
[0050] In some embodiments DC/DC converters 505a-505d can be switch-mode converters that are either isolated or non-isolated. In various embodiments isolated DC/DC converters 505a-505d may be preferable to isolate the downstream circuitry from potential failures of batteries 105a-105d. In some embodiments DC/DC converters 505a-505d can be, but are not limited to, the following architectures: step-down/buck, step-up boost, SEPIC, buck-boost or flyback. In further embodiments DC/DC converter 505a-505d can employ one or more solid-state switches that can include silicon, silicon-carbide, gallium-nitride or any other type of solid-state switch.
[0051]
[0052]
[0053] Although electric vehicle 700 is described and illustrated as one particular electric vehicle, embodiments of the disclosure are suitable for use with a multiplicity of electronic vehicles. For example, any electrically powered vehicle that receives at least part of its power from one or more batteries can be used with embodiments of the disclosure. In some instances, embodiments of the disclosure are particularly well suited for use with aerial vehicles because of the reliability and failure isolation of the power delivery circuits. Although a control circuit is not illustrated in each of circuits shown in
[0054] For simplicity, various active and passive circuitry components are not shown in the figures. In the foregoing specification, embodiments of the disclosure have been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the disclosure, and what is intended by the applicants to be the scope of the disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments can be combined in any suitable manner without departing from the spirit and scope of embodiments of the disclosure.
[0055] Additionally, spatially relative terms, such as bottom or top and the like can be used to describe an element and/or feature's relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a bottom surface can then be oriented above other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0056] Terms and, or, and an/or, as used herein, may include a variety of meanings that also is expected to depend at least in part upon the context in which such terms are used. Typically, or if used to associate a list, such as A, B, or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense. In addition, the term one or more as used herein may be used to describe any feature, structure, or characteristic in the singular or may be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and claimed subject matter is not limited to this example. Furthermore, the term at least one of if used to associate a list, such as A, B, or C, can be interpreted to mean any combination of A, B, and/or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.
[0057] Reference throughout this specification to one example, an example, certain examples, or exemplary implementation means that a particular feature, structure, or characteristic described in connection with the feature and/or example may be included in at least one feature and/or example of claimed subject matter. Thus, the appearances of the phrase in one example, an example, in certain examples, in certain implementations, or other like phrases in various places throughout this specification are not necessarily all referring to the same feature, example, and/or limitation. Furthermore, the particular features, structures, or characteristics may be combined in one or more examples and/or features.