# US 10,479,218 B2 · Electric vehicle power system with shared converter

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- Number: US 10,479,218 B2
- Document ID: US10479218B2
- Status: Granted
- Kind: B2
- Application number: 15/432,845
- Filed: 2017-02-14
- Published: 2018-08-16
- Granted: 2019-11-19
- Earliest claimed: 2017-02-14
- Assignees: Toyota Motor Engineering & Manufacturing North America, Inc.
- Applicants: Toyota Motor Engineering & Manufacturing North America, Inc.
- Inventors: Jae Seung Lee; Jongwon Shin; Ercan M. Dede
- Web page: https://patentgrep.com/patent/US10479218B2

## CPC

- B60L 50/13: using AC generators and AC motors
- B60L 15/007: {Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles}
- B60L 53/14: Conductive energy transfer
- B60L 53/22: Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
- B60L 53/24: Using the vehicle's propulsion converter for charging
- B60L 55/00: Arrangements for supplying energy stored within a vehicle to a power network, i.e. vehicle-to-grid [V2G] arrangements
- B60L 2210/10: DC to DC converters
- B60L 2210/30: AC to DC converters
- B60L 2210/40: DC to AC converters
- H02P 2201/09: Boost converter, i.e. DC-DC step up converter increasing the voltage between the supply and the inverter driving the motor
- Y02E 60/00: Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T 10/64: Electric machine technologies in electromobility
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- Y02T 10/7072: Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
- Y02T 10/72: Electric energy management in electromobility
- Y02T 90/12: Electric charging stations
- Y02T 90/14: Plug-in electric vehicles
- Y02T 90/16: Information or communication technologies improving the operation of electric vehicles
- Y04S 10/126: 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]
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y04S: SYSTEMS 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

## Abstract

Methods, systems, and apparatus for an electric vehicle. The system includes a battery control unit configured to be in a grid-connected mode or a stand-alone mode. The system includes a shared boost converter connected to a battery. The shared boost converter receives alternating current (AC) power, steps up voltage and converts the AC power to direct current (DC) power when the battery control unit is in the grid-connected mode. The shared boost converter receives DC power from the battery and steps up voltage when the battery control unit is in the stand-alone mode. The system also includes an inverter configured to receive the stepped up DC power when the battery control unit is in the stand-alone mode and convert the DC power to AC power. The system also includes a motor/generator connected to the inverter and configured to receive AC power for powering a drivetrain of the electric vehicle.

## Claims

### Claim 1

A power system for an electric vehicle in a grid-connected mode or in a stand-alone mode, the power system comprising:
a battery control unit configured to be in the grid-connected mode or the stand-alone mode based on operation of the electric vehicle;
a shared boost converter connected to a battery, the shared boost converter configured to:
receive power from an alternating current (AC) power source, step up voltage and convert the received AC power to direct current (DC) power, and output converted and stepped up DC power for storage in the battery when the battery control unit is in the grid-connected mode,
receive DC power from the battery, step up voltage of the received DC power, and output stepped up DC power when the battery control unit is in the stand-alone mode, and
receive generated DC power, step down voltage of the generated DC power, and output the stepped down DC power for storage in the battery when the battery control unit is in the stand-alone mode;
an inverter connected to the shared boost converter and configured to receive the stepped up DC power from the shared boost converter when the battery control unit is in the stand-alone mode, convert the received stepped up DC power to AC power, and output converted AC power; and
a motor/generator connected to the inverter and configured to receive the converted AC power for powering a drivetrain of the electric vehicle.

### Claim 2 (depends on 1)

The power system of claim 1, further comprising a first switch and a second switch each having a first state and a second state, and being connected to the battery control unit, the first switch located between the AC power source and the shared boost converter, and the second switch located between the shared boost converter and the battery,
wherein the first switch and the second switch are each set to the first state when the battery control unit is in the grid-connected mode, such that the shared boost converter connects the AC power source and the battery, and
wherein the first switch and the second switch are each set to the second state when the battery control unit is in the stand-alone mode, such that the shared boost converter connects the battery and the inverter.

### Claim 3 (depends on 1)

The power system of claim 1, further comprising a boost converter control unit connected to the shared boost converter and configured to implement a first control algorithm when the battery control unit is in the grid-connected mode, and a second control algorithm when the battery control unit is in the stand-alone mode, the first control algorithm causing the shared boost converter to step up voltage and convert the AC power received from the AC power source to DC power, and the second control algorithm causing the shared boost converter to step up voltage of the received DC power from the battery.

### Claim 4 (depends on 1)

The power system of claim 1, further comprising an isolated DC-DC converter connected to the shared boost converter and the battery, and configured to, when the battery control unit is in the grid-connected mode, receive the converted and stepped up DC power from the shared boost converter, and refine the received DC power for storage in the battery.

### Claim 5 (depends on 1)

The power system of claim 1, further comprising a filter connected to the AC power source and the shared boost converter, the filter configured to filter received AC power to comply with electromagnetic interference and/or electromagnetic compatibility requirements.

### Claim 6 (depends on 1)

The power system of claim 1, wherein the shared boost converter is further configured to receive stored DC power from the battery, step down voltage and convert the received stored DC power into AC power, and outputting the stepped down and converted AC power for providing to the AC power source when the battery control unit is in the grid-connected mode.

### Claim 7 (depends on 1)

The power system of claim 1, wherein the grid-connected mode and the stand-alone mode are mutually exclusive modes.

### Claim 8 (depends on 1)

The power system of claim 1, wherein the shared boost converter is coupled to a liquid cooling structure of a power control unit of the electric vehicle, for cooling the shared boost converter.

### Claim 9

A power system for an electric vehicle, the power system comprising:
a battery control unit configured to be in a grid-connected mode or a stand-alone mode based on operation of the electric vehicle; and
a shared boost converter connected to a battery, the shared boost converter configured to:
facilitate charging of the battery when the battery control unit is in the grid-connected mode by receiving power from an alternating current (AC) power source, stepping up voltage and converting the received AC power to direct current (DC) power, and outputting converted and stepped up DC power for storage in the battery,
facilitate charging of the battery when the battery control unit is in the stand-alone mode by receiving generated DC power, stepping down voltage of the generated DC power, and outputting the stepped down DC power for storage in the battery,
facilitate discharging of the battery when the battery control unit is in the grid-connected mode by receiving stored DC power from the battery, stepping down voltage and converting the received stored DC power into AC power, and outputting the stepped down and converted AC power for providing to the AC power source, and
facilitate discharging of the battery when the battery control unit is in the stand-alone mode by receiving DC power from the battery, stepping up voltage of the received DC power, and outputting stepped up DC power for powering a motor/generator of the electric vehicle.

### Claim 10 (depends on 9)

The power system of claim 9, further comprising an inverter connected to the shared boost converter and configured to:
receive the stepped up DC power from the shared boost converter and convert the received stepped up DC power to AC power when the shared boost converter facilitates discharge of the battery and the battery control unit is in the stand-alone mode; and
receive generated AC power from the motor/generator and convert the generated AC power to the generated DC power when the shared boost converter facilitates charging of the battery and the battery control unit is in the stand-alone mode.

### Claim 11 (depends on 9)

The power system of claim 9, further comprising a first switch and a second switch each having a first state and a second state, and being connected to the battery control unit, the first switch located between the AC power source and the shared boost converter, and the second switch located between the shared boost converter and the battery,
wherein the first switch and the second switch are each set to the first state when the battery control unit is in the grid-connected mode, such that the shared boost converter connects the AC power source and the battery, and
wherein the first switch and the second switch are each set to the second state when the battery control unit is in the stand-alone mode, such that the shared boost converter connects the battery and the motor/generator.

### Claim 12 (depends on 9)

The power system of claim 9, further comprising a boost converter control unit connected to the shared boost converter and configured to implement a first control algorithm when the battery control unit is in the grid-connected mode, and a second control algorithm when the battery control unit is in the stand-alone mode.

### Claim 13 (depends on 9)

The power system of claim 9, further comprising an isolated DC-DC converter connected to the shared boost converter and the battery, and configured to receive DC power and refine the received DC power.

### Claim 14 (depends on 9)

The power system of claim 9, further comprising a filter connected to the AC power source and the shared boost converter, the filter configured to filter received AC power to comply with electromagnetic interference and/or electromagnetic compatibility requirements.

### Claim 15 (depends on 9)

The power system of claim 9, wherein the shared boost converter is coupled to a liquid cooling structure of a power control unit of the electric vehicle, for cooling the shared boost converter.

### Claim 16

An electric vehicle connected to an AC power source in a grid-connected mode and disconnected from the AC power source in a stand-alone mode, the electric vehicle comprising:
a battery control unit configured to be in the grid-connected mode or the stand-alone mode;
a shared boost converter configured to:
step up voltage or step down voltage, and convert AC power to DC power or convert DC power to AC power when the battery control unit is in the grid-connected mode, and
step up voltage or step down voltage when the battery control unit is in the stand-alone mode;
an inverter coupled to the shared boost converter and configured to convert AC power to DC power or convert DC power to AC power when the battery control unit is in the stand-alone mode;
a first switch and a second switch each having a first state and a second state, and each being connected to the battery control unit, the first switch located between the AC power source and the shared boost converter, and the second switch located between the shared boost converter and the battery, the first switch and the second switch each being set to the first state when the battery control unit is in the grid-connected mode such that the shared boost converter connects the AC power source and the battery, and the first switch and the second switch each being set to the second state when the battery control unit is in the stand-alone mode such that the shared boost converter connects the battery and the inverter; and
a motor/generator connected to the inverter and configured to receive AC power from the battery via the inverter for powering a drivetrain of the electric vehicle or generate AC power for charging the battery.

### Claim 17 (depends on 16)

The electric vehicle of claim 16, further comprising a boost converter control unit connected to the shared boost converter and configured to implement a first control algorithm when the battery control unit is in the grid-connected mode, and a second control algorithm when the battery control unit is in the stand-alone mode.

### Claim 18 (depends on 16)

The electric vehicle of claim 16, wherein the shared boost converter is coupled to a liquid cooling structure of a power control unit, for cooling the shared boost converter.