# US 12,214,684 B2 · System and method for charging electric vehicles

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- Number: US 12,214,684 B2
- Document ID: US12214684B2
- Status: Granted
- Kind: B2
- Application number: 17/601,762
- Filed: 2021-03-08
- Published: 2022-06-23
- Granted: 2025-02-04
- Earliest claimed: 2020-03-06
- Assignees: Zhejiang Hanmingbo New Energy Co., Ltd.
- Applicants: Zhejiang Hanmingbo New Energy Co., Ltd.
- Inventors: Zhengmao Zhu
- Web page: https://patentgrep.com/patent/US12214684B2

## CPC

- B60L 53/24: Using the vehicle's propulsion converter for charging
- H02J 7/02: for charging batteries from AC mains by converters
- H02J 7/855: {with circuits adapted for supplying loads from the battery}
- H02J 7/865: {Battery or charger load switching, e.g. concurrent charging and load supply (H02J7/50 takes precedence)}
- H02K 3/28: Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32)
- H02K 11/049: Rectifiers associated with stationary parts, e.g. stator cores
- H02K 11/33: Drive circuits, e.g. power electronics (H02K11/38 takes precedence)
- H02M 1/4225: {using a non-isolated boost converter}
- H02M 3/33573: {Full-bridge at primary side of an isolation transformer}
- H02P 27/08: with pulse width modulation
- B60L 2210/14: Boost converters
- H02J 2207/20: Charging or discharging characterised by the power electronics converter
- 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 10/92: Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
- Y02T 90/12: Electric charging stations
- Y02T 90/14: Plug-in electric vehicles
- 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
- H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- H02M: APPARATUS 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 (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

The present teaching relates to method and system for charging a rechargeable battery deployed in an electric apparatus. The system resides in the electric apparatus. The system comprises a motor, an inverter, an output rectifier, a configurator, and a controller. The motor comprises a stator having a plurality of stator teeth and a plurality of stator windings wounded on the plurality of stator teeth. The inverter comprises a plurality of power switch devices. The configurator comprises a plurality of contactors coupled with the plurality of stator windings and the plurality of power switch devices. The controller controls the plurality of power switch devices and the plurality of contactors, so as to configure the system to operate in one of a traction mode and a charging mode.

## Claims

### Claim 1

A reconfigurable traction-charging system residing in an electric apparatus having a rechargeable battery, comprising:
a motor comprising a stator having a plurality of stator teeth and a plurality of stator windings wounded on the plurality of stator teeth, wherein a stator winding on at least one stator tooth of the motor is split into two or more coils;
an inverter comprising a plurality of power switch devices;
an output rectifier;
a configurator comprising a plurality of contactors coupled with the plurality of stator windings and the plurality of power switch devices; and
a controller for controlling the plurality of power switch devices and the plurality of contactors, so as to configure the reconfigurable traction-charging system to operate in one of a traction mode and a charging mode,
wherein:
under the traction mode, the rechargeable battery supplies electric energy to the motor via the inverter; and
under the charging mode, connections associated with the plurality of power switch devices and the stator windings are configured by the configurator to form a charger that draws electric energy from an external power supply to charge the rechargeable battery, and wherein
a stator winding on at least one stator tooth of the motor is split into two or more coils;
under the charging mode, the two or more coils and the corresponding at least one stator tooth form a transformer in the charger; and
under the traction mode, the two or more coils are connected in parallel or in series to form a phase winding.

### Claim 2 (depends on 1)

The reconfigurable traction-charging system of claim 1, wherein
the external power supply is a multiple phase power supply;
the system further comprises an input bridge rectifier; and
the input bridge rectifier, the charger, and the output rectifier form a charging power path having two stages, including a first stage being a bridge rectifier front end with a Boost converter and a second stage being an isolated DC/DC rear end.

### Claim 3 (depends on 2)

The reconfigurable traction-charging system of claim 2, wherein at least one stator winding on one or more stator teeth of the motor constitutes at least one Boost inductor of the Boost converter.

### Claim 4 (depends on 1)

The reconfigurable traction-charging system of claim 1, wherein
the external power supply is a single or split single phase power supply;
the system further comprises an input bridge rectifier; and
the input bridge rectifier, the charger, and the output rectifier form a charging path having two stages, including a first stage being a bridge PFC rectifier front end with a Boost converter and a second stage being an isolated DC/DC rear end.

### Claim 5 (depends on 4)

The reconfigurable traction-charging system of claim 4, wherein at least one stator winding on one or more stator teeth of the motor constitutes at least one Boost inductor of the Boost converter.

### Claim 6 (depends on 1)

The reconfigurable traction-charging system of claim 1, wherein
the external power supply is a multiple phase power supply; and
the charger and the output rectifier form a charging path having two stages, including a first stage being a multiple phase Boost PFC front end and a second stage being an isolated DC/DC rear end.

### Claim 7 (depends on 1)

The reconfigurable traction-charging system of claim 1, wherein
the external power supply is a single phase or single split phase power supply; and
the charger and the output rectifier form a charging path having two stages, including a first stage being a single phase Boost PFC front end and a second stage being an isolated DC/DC rear end.

### Claim 8 (depends on 1)

The reconfigurable traction-charging system of claim 1, wherein
the external power supply is a single phase or single split phase power supply; and
the system further comprises two diodes, wherein the two diodes, the charger, and the output rectifier form a charging path having two stages, including a first stage being a single phase Totem-Pole Boost PFC front end stage and a second stage being an isolated DC/DC rear end stage.

### Claim 9

A method for implementing a reconfigurable traction-charging system residing in an electric apparatus having a rechargeable battery, the method comprising:
configuring, via a configurator, under control of a controller, the reconfigurable traction-charging system to operate in a traction mode;
upon receiving a request to charge the rechargeable battery, configuring, via the configurator, the reconfigurable traction-charging system to operate in a charging mode; and
upon determining that a criterion associated the rechargeable battery is met, configuring, via the configurator, the reconfigurable traction-charging system to operate in the traction mode,
wherein: the reconfigurable traction-charging system comprises the controller, the configurator, a motor, an inverter and an output rectifier;
the motor comprises a stator having a plurality of stator teeth and a plurality of stator windings wound on the plurality of stator teeth, wherein a stator winding on at least one stator tooth of the motor is split into two or more coils, wherein the two or more coils have distinct connections for the traction mode and the charging mode;
the inverter comprises a plurality of power switch devices, the configurator comprises a plurality of contactors coupled with the plurality of stator windings and the plurality of power switch devices
wherein
under the traction mode, the rechargeable battery supplies electric energy to the motor via the inverter; and
under the charging mode, connections associated with the plurality of power switch devices and the stator windings are configured by the configurator to form a charger that draws electric energy from an external power supply to charge the rechargeable battery, and wherein
a stator winding on at least one stator tooth of the motor is split into two or more coils;
under the charging mode, the two or more coils and the corresponding at least one stator tooth form a transformer in the charger; and
under the traction mode, the two or more coils are connected in parallel or in series to form a phase winding.

### Claim 10 (depends on 9)

The method for implementing a reconfigurable traction-charging system of claim 9, wherein
the external power supply is a multiple phase power supply;
the reconfigurable traction-charging system further comprises an input bridge rectifier; and
the input bridge rectifier, the charger, and the output rectifier form a charging power path having two stages, including a first stage being a bridge rectifier front end with a Boost converter and a second stage being an isolated DC/DC rear end.

### Claim 11 (depends on 10)

The method for implementing a reconfigurable traction-charging system of claim 10, wherein at least one stator winding on one or more stator teeth of the motor constitutes at least one Boost inductor of the Boost converter.

### Claim 12 (depends on 9)

The method for implementing a reconfigurable traction-charging system of claim 9, wherein
the external power supply is a single or split single phase power supply;
the reconfigurable traction-charging system further comprises an input bridge rectifier; and
the input bridge rectifier, the charger, and the output rectifier form a charging path having two stages including a first stage being a bridge PFC rectifier front end with a Boost converter and a second stage being an isolated DC/DC rear end.

### Claim 13 (depends on 12)

The method for implementing a reconfigurable traction-charging system of claim 12, wherein at least one stator winding on one or more stator teeth of the motor constitutes at least one Boost inductor of the Boost converter.

### Claim 14 (depends on 9)

The method for implementing a reconfigurable traction-charging system of claim 9, wherein
the external power supply is a multiple phase power supply; and
the charger and the output rectifier form a charging path having two stages, including a first stage being a multiple phase Boost PFC front end and a second stage being an isolated DC/DC rear end.

### Claim 15 (depends on 9)

The method for implementing a reconfigurable traction-charging system of claim 9, wherein
the external power supply is a single phase or single split phase power supply; and
the charger and the output rectifier form a charging path having two stages, including a first stage being a single phase Boost PFC front end and a second stage being an isolated DC/DC rear end.

### Claim 16 (depends on 9)

The method for implementing a reconfigurable traction-charging system of claim 9, wherein
the external power supply is a single phase or single split phase power supply; and
the reconfigurable traction-charging system further comprises two diodes, wherein the two diodes, the charger, and the output rectifier form a charging path having two stages, including a e second stage being an isolated DC/DC rear end stage.