# US 9,520,741 B2 · System for charging electrical storage device and method of making same

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- Number: US 9,520,741 B2
- Document ID: US9520741B2
- Status: Granted
- Kind: B2
- Application number: 13/304,791
- Filed: 2011-11-28
- Published: 2013-05-30
- Granted: 2016-12-13
- Earliest claimed: 2011-11-28
- Assignees: General Electric Company
- Applicants: Viswanathan Kanakasabai
- Inventors: Viswanathan Kanakasabai
- Web page: https://patentgrep.com/patent/US9520741B2

## CPC

- H02J 7/1423: {with multiple batteries}
- B60L 1/003: {to auxiliary motors, e.g. for pumps, compressors}
- B60L 7/14: for vehicles propelled by AC motors
- B60L 15/007: {Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles}
- B60L 50/40: using propulsion power supplied by capacitors
- B60L 50/51: characterised by AC-motors
- B60L 58/12: responding to state of charge [SoC]
- B60L 58/40: for controlling a combination of batteries and fuel cells
- H02J 1/08: Three-wire DC power distribution systems; Systems having more than three wires
- B60L 2200/22: Microcars, e.g. golf cars
- B60L 2210/14: Boost converters
- B60L 2240/547: Voltage
- B60L 2240/622: by satellite navigation
- H02J 7/1438: {in combination with power supplies for loads other than batteries}
- H02J 2105/37: exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV]
- H02M 1/009: {having two or more independently controlled outputs (for DC-DC converter with intermediate AC H02M3/33561)}
- H02M 3/158: including plural semiconductor devices as final control devices for a single load
- H02M 3/335: using semiconductor devices only
- Y02T 10/64: Electric machine technologies in electromobility
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- Y02T 10/72: Electric energy management in electromobility
- Y02T 90/16: Information or communication technologies improving the operation of electric vehicles
- Y02T 90/40: Application of hydrogen technology to transportation, e.g. using fuel cells
- Y10T 29/49117: Conductor or circuit manufacturing
- H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- 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
- 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)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A system for charging an electrical storage device includes a motor drive, a DC link electrically coupled to the motor drive, and a first leg coupled to the DC link that includes a first power switch coupled in series with a second power switch via a first node. A first inductor is coupled to the first node, and a first energy storage device (ESD) is electrically coupled to the first inductor. A second leg is coupled to the DC link that includes a third power switch coupled in series with a fourth power switch via a second node. A charging circuit includes a transformer coupled to the first and second nodes. A second ESD is coupled to receive charging energy from the transformer, and a controller is configured to cause a first voltage mismatch between the first and second nodes to generate the charging energy.

## Claims

### Claim 1

A propulsion system comprising:
a motor drive;
a direct current (DC) link electrically coupled to the motor drive;
a first leg coupled to the DC link and comprising a first power switch coupled in series with a second power switch via a first node;
a first inductor coupled to the first node, wherein the first leg and inductor form a first bi-directional DC-DC voltage converter;
a first energy storage device (ESD) electrically coupled to the first inductor;
a second leg coupled to the DC link and comprising a third power switch coupled in series with a fourth power switch via a second node;
a second inductor coupled to the second node, wherein the second leg and second inductor form a second bi-directional DC-DC voltage converter;
a charging circuit comprising a transformer having a first terminal coupled to the first node and having a second terminal coupled to the second node;
a second ESD coupled to receive charging energy from the transformer; and
a controller coupled to the first and second legs and configured to cause a first variable voltage difference between the first and second nodes during an interleave duration of a frequency period to generate the charging energy, wherein the second ESD can be charged during operation of the motor drive.

### Claim 2 (depends on 1)

The propulsion system of claim 1 wherein the controller is further configured to vary the interleave duration based on a desired amount of the charging energy to be supplied to the second ESD.

### Claim 3 (depends on 1)

The propulsion system of claim 1 wherein the first ESD has a higher voltage capacity than the second ESD.

### Claim 4 (depends on 1)

The propulsion system of claim 1 wherein the first ESD is electrically coupled to the second inductor.

### Claim 5 (depends on 4)

The propulsion system of claim 4 wherein the controller, in being configured to cause the first voltage difference, is configured to operate the first and second legs in a boost mode to boost a voltage of the first ESD to the DC link.

### Claim 6 (depends on 1)

The propulsion system of claim 1 wherein the controller is further configured to cause a voltage match between the first and second nodes to eliminate the charging energy.

### Claim 7 (depends on 6)

The propulsion system of claim 6 wherein the controller is further configured to cause a second voltage difference between the first and second nodes during the frequency period to generate the charging energy, wherein the first and second voltage differences have a duration equal to the interleave duration.

### Claim 8 (depends on 1)

The propulsion system of claim 1 wherein the transformer comprises:
a first winding coupled to the first and second terminals; and
a second winding; and
wherein the charging circuit further comprises:
a plurality of diodes coupled to the second winding; and
an inductor coupled between the plurality of diodes and the second ESD.

### Claim 9 (depends on 8)

The propulsion system of claim 8 wherein the plurality of diodes comprises a full-wave diode bridge.

### Claim 10 (depends on 8)

The propulsion system of claim 8 wherein the transformer further comprises a winding tap coupled to the second winding; and
wherein the second ESD is further coupled to the winding tap.

### Claim 11 (depends on 1)

The propulsion system of claim 1 further comprising a third pair of power switches comprising a fifth power switch coupled in series with a sixth power switch via a third node.

### Claim 12

A method of assembling a control system comprising:
coupling a first energy storage device (ESD) to a first bi-directional DC-DC converter, the first bi-directional DC-DC converter comprising:
a first pair of power switches coupled in series; and
an inductor coupled to a first node formed between the first pair of power switches;
coupling the first ESD to a second bi-directional DC-DC converter, the second bi-directional DC-DC converter comprising:
a second pair of power switches coupled in series; and
an inductor coupled to a second node formed between the second pair of power switches;
coupling the first and second bi-directional DC-DC converters to a DC link;
coupling the DC link to a motor drive;
coupling a transformer of a charge circuit to the first and second nodes;
coupling a second ESD to the charge circuit to receive a charge voltage therefrom; and
coupling a controller to the first and second bi-directional DC-DC converters and configuring the controller to interleave control of the first and second bi-directional DC-DC converters to cause a variable voltage difference between the first and second nodes during an interleave portion of a frequency period to generate the charge voltage, wherein the second ESD can be charged during operation of the motor drive.

### Claim 13 (depends on 12)

The method of claim 12 further comprising configuring the controller to:
increase the interleave portion of the frequency period to increase the amount of charge voltage generated; and
decrease the interleave portion of the frequency period to decrease the amount of charge voltage generated.

### Claim 14 (depends on 12)

The method of claim 12 wherein coupling the first ESD to the first bi-directional DC-DC converter comprises coupling a first battery having a first voltage rating to the first bi-directional DC-DC converter;
wherein coupling the second ESD to the charge circuit comprises coupling a second battery having a second voltage rating to the charge circuit; and
where the second voltage rating is lower than the first voltage rating.

### Claim 15 (depends on 14)

The method of claim 14 further comprising coupling an auxiliary load to the second ESD.

### Claim 16

An energy storage arrangement for an electrically powered system, the arrangement comprising:
a first bi-directional DC-DC converter comprising:
a first pair of power switches comprising a first power switch coupled in series with a second power switch via a first node; and
a first inductor coupled to the first node;
a first energy storage device coupled to the first inductor;
a DC link comprising:
a first bus coupled to the first bi-directional DC-DC converter; and
a second bus coupled to the first bi-directional DC-DC converter;
a second pair of power switches comprising:
a third power switch coupled to the first bus; and
a fourth power switch coupled to the second bus and coupled in series with the third power switch via a second node;
a second inductor coupled to the first energy storage device;
a transformer having a first winding comprising:
a first terminal coupled to the first node; and
a second terminal coupled to the second node;
a second energy storage device coupled to receive a charge voltage from the transformer;
a controller coupled to the first and second pairs of power switches and configured to cause a voltage difference between the first and second nodes during an interleave portion of a frequency period to generate the charge voltage; and
an inductor switch coupled between the second inductor and the second node, wherein the controller is further configured to:
close the inductor switch; and
control the second pair of power switches to cause the second pair of power switches to boost a voltage of the first energy storage device to the DC link.

### Claim 17 (depends on 16)

The energy storage arrangement of claim 16 wherein the first energy storage device comprises a battery having a first voltage rating, and wherein the second energy storage device comprises a battery having a second voltage rating lower than the first energy storage device.

### Claim 18 (depends on 16)

The method of claim 16 wherein the controller is further configured to:
open the inductor switch; and
control the first and second pair of power switches as a phase-shifted converter.

### Claim 19 (depends on 17)

The energy storage arrangement of claim 17 wherein the controller is further configured to vary the interleave portion based on a desired amount of the charge voltage to be supplied to the second energy storage device.

### Claim 20

A propulsion system comprising:
a motor drive;
a direct current (DC) link electrically coupled to the motor drive;
a first leg coupled to the DC link and comprising a first power switch coupled in series with a second power switch via a first node;
a first inductor coupled to the first node, wherein the first leg and inductor form a first bi-directional DC-DC voltage converter;
a first energy storage device (ESD) electrically coupled to the first inductor;
a second leg coupled to the DC link and comprising a third power switch coupled in series with a fourth power switch via a second node;
a charging circuit comprising a transformer having a first terminal coupled to the first node and having a second terminal coupled to the second node;
a second ESD coupled to receive charging energy from the transformer; and
a controller coupled to the first and second legs and configured to cause a variable voltage difference between the first and second nodes during an interleave duration of a frequency period to generate the charging energy, wherein the second ESD can be charged during operation of the motor drive.