Smart Power Hub

An Electric Vehicle (EV) smart power hub comprising:

• an Alternating Current (AC) port for connecting to an AC power grid;
• a first Direct Current (DC) port for connecting to a primary battery onboard the EV that powers a drive train of the EV;
• a second DC port for providing auxiliary DC power to instruments onboard the EV;
• an AC converter that converts AC applied to the AC port from the AC power grid to a DC link voltage during an AC grid to battery voltage (G2V) mode;
• a DC bi-directional converter (DBC) that converts the DC link voltage from the AC converter to a battery voltage applied to the primary battery through the first DC port, the DBC converting the battery voltage applied to the first DC port from the primary battery to a DC load voltage applied to the second DC port when the DC bi-directional converter is operating in a battery voltage to load (V2L) mode;
• an AC digital controller that configures the AC converter for operating modes including the G2V mode and that controls the AC converter to convert AC power to the DC link voltage during the G2V mode;
• and
• a DBC digital controller that configures the DBC for operating modes including the G2V mode and the V2L mode, the DBC digital controller generating control signals to operate the DC bi-directional converter to convert the DC link voltage to the battery voltage during the G2V mode, and to convert the battery voltage to the DC link voltage during the V2L mode,
• wherein EV smart power hub is located onboard the EV and is configured for operating modes including the G2V mode and the V2L mode.

A power hub comprising:

• an Alternating Current (AC) port having three lines for carrying three-phase AC, the AC port also for receiving single-phase AC on a first line and on a third line of the three lines,
• a first switch for connecting a second line of the three lines to the first line when the AC port receives single-phase AC, and for isolating the first line from the second line when the AC port receives three-phase AC;
• an AC bi-directional converter (ABC) having three pairs of an upper transistor and a lower transistor, each pair receiving one of the three lines on a node connecting the upper transistor to the lower transistor;
• an ABC digital controller that opens the first switch and that generates first Pulse-Width-Modulation (PWM) control signals to the upper and lower transistors, the first PWM control signals causing the ABC to operate as a three-phase AC rectifier with each pair of transistors rectifying one of three AC phases when three-phase AC is received,
• when the three-phase AC is not received and the single-phase AC is received, the ABC digital controller closes the first switch to short together the first line and the second line from the AC port, the ABC digital controller generating the first PWM control signals to interleave operation of a first and second pair of the upper and lower transistors that connect to the first line and to second line that are connected together by the first switch, and operates a third pair of the upper and lower transistors that are connected to the third line at a line frequency of the single-phase AC;
• a link capacitor having a ground terminal connected to the lower transistors and an upper terminal connected to the upper transistors, the upper terminal having a DC link voltage;
• a first DC port for connecting to a primary battery;
• a second DC port for connecting to a DC load;
• a DC bi-directional converter (DBC) having a first bridge of first bridge transistors that receive the DC link voltage, and a second bridge of second bridge transistors that connect to the first DC port, and auxiliary transistors that connect to the second DC port, and a transformer with primary windings connected in a first loop with a first capacitor and a first inductor to the first bridge transistors, secondary windings connected in a second loop with a second capacitor and a second inductor to the second bridge transistors, and auxiliary windings connected in a third loop to the auxiliary transistors;
• a second switch that opens and closes the first loop and opens and closes the third loop;
• and
• a DBC digital controller that operates the second switch and generates Pulse-Frequency-Modulation (PFM) control signals and synchronous control signals;
• wherein during a charging mode, the DBC digital controller operates the second switch to close the first loop and open the third loop, the DBC digital controller applying the PFM control signals to the first bridge transistors and applies the synchronous control signals to the second bridge transistors to operate the DBC as a CLLLC resonant power converter to charge the primary battery on the first DC port from the DC link voltage on the link capacitor;
• wherein during a discharging mode, the DBC digital controller operates the second switch to open the first loop and close the third loop, the DBC digital controller applying the PFM control signals to the second bridge transistors and applies the synchronous control signals to the auxiliary transistors to operate the DBC as a phase-shift full bridge of the second bridge transistors with a synchronous rectification by the auxiliary transistors to drive the second DC port from the primary battery on the first DC port.