Method and apparatus for producing tractive effort with interface to other apparatus

An apparatus and method for determining and providing a controlled power from a first apparatus to another apparatus is disclosed. The apparatus includes an energy source configured to generate a power output, a power converter electrically connected to the energy source to receive the power output and to output a conditioned power, and a transfer switch configured to selectively couple the conditioned power to an external apparatus. The apparatus also includes a controller in communication with the external apparatus and configured to receive apparatus parameter data related to the external apparatus, determine a power requirement of the external apparatus based on the apparatus parameter data, operate the power convertor to output conditioned power that meets the power requirement of the external apparatus, and control the transfer switch to couple the conditioned power that meets the power requirement to the external apparatus.

BACKGROUND OF THE INVENTION

The invention relates generally to an apparatus for producing tractive effort and, more particularly, to an apparatus and method for determining and providing a controlled power from a first apparatus to another apparatus.

Recently, electric vehicles and plug-in hybrid electric vehicles have become increasingly popular. These vehicles are typically powered by an energy storage system including one or more batteries, either alone or in combination with an internal combustion engine. In electric vehicles, the one or more batteries power the entire drive system, thereby eliminating the need for an internal combustion engine. Plug-in hybrid electric vehicles, on the other hand, include a small internal combustion engine to supplement the battery power, which greatly increases the fuel efficiency of the vehicle.

In conventional internal combustion engine (ICE) vehicles, the range is typically limited by the amount of fuel stored in the tank. If the length of travel exceeds the amount of stored energy, i.e. fuel in the tank, operation of the vehicle is stopped until additional fuel is added to the tank from a storage container or service truck. Likewise, if the useable energy in the conventional vehicle's 12 V Starting, Lighting, Ignition (SLI) battery is insufficient to start the heat engine, the SLI battery can be jump started using another vehicle via a set of jumper cables or a service truck can provide a “boost” charge via a separate 12 V battery or from a portable engine driven generator.

In today's Hybrid Vehicles (HEV's) and future Plug-in Hybrid Vehicles (PHEV), if the amount of useable stored on-board electric energy is below a given threshold but there is fuel in the tank, generally the vehicle will operate, but with reduced performance, (acceleration and hill climbing ability) and reduced fuel economy while the heat engine runs providing power to propel the vehicle and also to recharge the electrical storage unit(s). In the event that both the electrical energy storage unit is depleted and there is no fuel in the tank, then the entire propulsion drive is not operational and the vehicle will require either charging of the on-board traction battery from another source/vehicle to allow operation on the electric drive alone or the addition of fuel to the tank and provision of sufficient electrical energy to start the engine. However, in existing HEVs, there is no apparatus or associated control means that allow either cranking of the engine or charging of the traction energy storage unit from another vehicle due to non-standard voltage ratings of the energy storage unit(s).

Similarly, in today's pure electric vehicles (EVs), if the amount of useable stored on-board electric energy is below a given threshold, then the electric propulsion drive is not operational and the vehicle will require charging of the on-board traction battery from another source/vehicle. The ability to jump start the EV from another vehicle (conventional ICE, Hybrid, or Electric) is not normally an option due to non-standard voltage ratings of the energy storage unit(s), and lack of appropriate interface controls. Similarly, if a service truck is requested for assistance, the service truck generally is not equipped to provide a charge to the traction batteries of the electric vehicle. Based on the inability of existing cars and tow trucks to jump start the electric vehicle, it is often necessary to tow the electric vehicle to a garage or facility with proper charging equipment.

Therefore, a need exists for an apparatus and associated control means that allow one electric or hybrid vehicle or apparatus with relatively large amount of stored on-board energy to be used to either crank the engine or charge the traction energy storage unit in another vehicle or apparatus.

BRIEF DESCRIPTION OF THE INVENTION

The invention is a directed method and apparatus for determining and providing a controlled power from a first apparatus to another apparatus

In accordance with one aspect of the invention, an apparatus includes an energy source configured to generate a power output, a power converter electrically connected to the energy source to receive the power output and to output a conditioned power, and a transfer switch configured to selectively couple the conditioned power to an external apparatus. The apparatus also includes a controller in communication with the external apparatus and configured to receive apparatus parameter data related to the external apparatus, determine a power requirement of the external apparatus based on the apparatus parameter data, operate the power convertor to output conditioned power that meets the power requirement of the external apparatus, and control the transfer switch to couple the conditioned power that meets the power requirement to the external apparatus.

In accordance with another aspect of the invention, a method for providing power to an external apparatus includes the step of interfacing a charging apparatus with the external apparatus, the charging apparatus comprising a energy source configured to generate a power output and a transfer switch configured to selectively electrically couple the charging apparatus to the external apparatus. The method also includes the steps of receiving apparatus parameter data on the external apparatus, determining a power requirement of the external apparatus based on the apparatus parameter data, controlling the transfer switch to electrically couple the charging apparatus to the external apparatus, and transferring power from the charging apparatus to the external apparatus at the determined power requirement.

In accordance with yet another aspect of the invention, a control system for controlling a supply of power from a vehicular energy source is programmed to receive apparatus parameter data of an external vehicular energy source and determine a power requirement of the external vehicular energy source based on the apparatus parameter data. The control system is further programmed to cause a power converter electrically connected to the vehicular energy source to generate conditioned power that meets the power requirement of the external vehicular energy source and actuate a transfer switch connected to the power converter source to electrically couple the power converter and the external vehicular energy source, thereby transferring the conditioned power from the power converter to the external vehicular energy source.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Embodiments of the invention are directed to systems and methods for determining and providing a controlled power from a first apparatus to another apparatus. The system includes an apparatus for producing tractive effort, a power converter configured to receive a power output from the apparatus and output a conditioned power, and a transfer switch to selectively couple the conditioned power to an external apparatus. The system also includes a controller in communication with the external apparatus and configured to receive apparatus parameter data from the external apparatus, determine a power requirement of the external apparatus based on the apparatus parameter data, operate the power convertor to output conditioned power that meets the power requirement of the external apparatus, and control the transfer switch to couple the conditioned power meeting the power requirement to the external apparatus.

FIG. 1illustrates a block diagram of an apparatus10for providing a controlled power. According to an exemplary embodiment of the invention, apparatus10is configured as an apparatus for producing tractive effort and is incorporated into an electric or hybrid-electric vehicle. As shown inFIG. 1, apparatus10for producing tractive effort comprises an energy source12, a motor drive14, and a motor16. In operation, energy source12generates a high DC voltage18. Motor drive14generates a motor voltage20from high DC voltage18, and motor16produces tractive effort from motor voltage20. As used herein, motor16refers to any electrical apparatus capable of producing mechanical power from electrical power including, without limitation, single phase or multiple phase, AC (alternating current) or DC motors.

In the embodiment ofFIG. 1, energy source12is configured as a hybrid-electric energy source that comprises a heat engine22, an alternator24, a rectifier26, a traction/energy battery28, and a traction boost converter30. Traction boost converter30is sometimes referred to as bi-directional DC-DC converter, or a bi-directional boost/buck converter that functions to decouple the voltage between the input and the output of the device while efficiently transferring power. In operation, heat engine22generates mechanical power32by burning a fuel. Alternator24generates an alternating voltage34from mechanical power32and rectifier26then rectifies alternating voltage34to produce a low DC voltage36. Energy battery28stores and delivers energy derived from low DC voltage36, and traction boost converter30boosts low DC voltage36to produce high DC voltage18. As used herein in reference to DC voltages, “low” and “high” are relative terms only and imply no particular absolute voltage levels. The high DC voltage18is transferred to motor drive14, which includes therein a traction converter38that receives high DC voltage18and, responsive thereto, generates motor voltage20from high DC voltage18during motoring operation. Additionally, traction converter38generates high DC voltage18from motor voltage20during braking operation. During a braking operation, the high DC voltage18is produced from motor voltage20and the power flow is from the high voltage side18of the bi-directional DC-DC converter30to the lower voltage side36of the bi-directional DC-DC converter30through a “buck” mode of operation.

As further shown inFIG. 1, apparatus10includes a power converter40and a controller42(i.e., vehicle system controls) configured to control operation of the power converter40. According to one embodiment of the invention, power converter40includes therein a bi-directional cranking inverter44and charging boost converter46. A transfer switch48is also included in apparatus10and is controlled by controller42to selectively couple the power converter40to components of the apparatus10and/or an external apparatus50. During normal operation of the apparatus10to produce tractive effort, controller42operates power converter40and transfer switch48to receive/provide power from/to energy source12. During a “cranking operation,” in which alternator24is used as a motor to apply torque for cranking and/or starting heat engine22, controller42controls cranking inverter to generate a cranking voltage52at a desired frequency from low DC voltage36. The transfer switch48is then controlled to selectively couple the cranking voltage52to alternator24. Alternatively, during a charging operation, controller42controls charging boost converter46to boost alternating voltage34to a higher voltage more suitable for charging energy/traction battery28.

According to an embodiment of the invention, power generated by apparatus10is conditioned and controlled for transfer to an external apparatus50during a “transfer” mode of operation. During this “transfer” mode of operation, controller42acts to control operation of power converter40and transfer switch48to selectively provide a conditioned power54to the external apparatus50. The conditioned power can be supplied to, for example, crank an engine (not shown) in the external device50and/or recharge an energy storage system (not shown) in the external device50. When operating in transfer mode, controller42acts to receive apparatus parameter data from the external apparatus50, which can include a battery voltage, a battery rate, a battery state-of-charge, and a vehicle make and model of the external apparatus. Based on this external apparatus parameter data, the controller42determines a power requirement of the external apparatus50and operates the power convertor40to output conditioned power that meets the power requirement of the external apparatus50(e.g., cranking voltage at a desired frequency). The controller42can then control operation of the transfer switch48to couple the conditioned power to the external apparatus50.

Referring now toFIG. 2, apparatus10is shown interfaced with a similar external apparatus50so as to provide cranking power or recharging power thereto during the transfer mode of operation. In the embodiment ofFIG. 2, apparatus10is incorporated into a hybrid-electric vehicle and supplies power to external apparatus50, which is also incorporated into a hybrid-electric vehicle. External apparatus50comprises an apparatus for producing tractive effort and includes therein an energy source56, a motor drive58, and a motor60. In operation, energy source56generates a high DC voltage62. Motor drive58generates a motor voltage64from high DC voltage62, and motor60produces tractive effort from motor voltage64.

In the embodiment ofFIG. 2, energy source56is configured as a hybrid-electric energy source that comprises a heat engine66, an alternator68, a rectifier70, an energy/traction battery72, and a traction boost converter74. In operation, heat engine66generates mechanical power76by burning a fuel. Alternator68generates an alternating voltage78from mechanical power76and rectifier70then rectifies alternating voltage78to produce a low DC voltage80. Energy battery72stores and delivers energy derived from low DC voltage80, and traction boost converter74boosts low DC voltage80to produce high DC voltage62. The high DC voltage62is transferred to motor drive58, which includes therein a traction converter82that receives high DC voltage62and, responsive thereto, generates motor voltage64from high DC voltage62during motoring operation. Additionally, traction converter82generates high DC voltage62from motor voltage64during braking operation.

As further shown inFIG. 2, external apparatus50includes a power converter84and a controller86configured to control operation of the power converter84. According to one embodiment of the invention, power converter84includes therein a bi-directional cranking inverter88and charging boost converter90. A transfer switch92is also included in external apparatus50and is controlled by controller86to selectively couple the power converter84to components of the external apparatus50and/or to apparatus10. During normal operation of the external apparatus50to produce tractive effort, controller86operates power converter84and transfer switch92to receive/provide power from/to energy source56. During a “cranking operation,” in which alternator68is used as a motor to apply torque for cranking and/or starting heat engine66, controller86controls cranking inverter88to generate a cranking voltage94at a desired frequency from low DC voltage80. The transfer switch92is then controlled to selectively couple the cranking voltage94to alternator68. Alternatively, during a charging operation, controller86controls charging boost converter90to boost alternating voltage78to a higher voltage more suitable for charging energy battery72.

According to an embodiment of the invention, when it is desired to transfer power from apparatus10to external apparatus50, such as when traction battery72is depleted, an electrical interface cable96is used to connect the apparatus10to the external apparatus50. As shown inFIG. 2, the electrical interface cable96is connected to the transfer switches48,92to allow for the transfer of conditioned power54therebetween. According to an embodiment of the invention, controller42is configured to determine when the electrical interface cable96is connected to transfer switch48. When controller42determines that the electrical interface cable96is connected to transfer switch48, controller42actuates or controls transfer switch48to electrically couple apparatus10to external apparatus50, so as to allow for transfer of conditioned power54therebetween.

Controller42is further configured to communicate with controller86in order to determine what level of power (i.e., current and voltage levels/frequency) is needed to either recharge traction battery72and/or crank heat engine66. That is, controller42receives from controller86(such as through wireless communication or using electrical interface cable96, for example) apparatus parameter data on the external apparatus50, which can include a battery voltage, a battery rate, battery temperature, or a battery state-of-charge of traction battery72, a fuel level, and/or a vehicle make and model of the vehicle in which external apparatus50is incorporated. Alternatively, it is also recognized that the apparatus parameter data related to the external apparatus50could be manually input into controller42.

Based on the received apparatus parameter data, controller42is programmed to determine a power requirement of the external apparatus50. That is, based on the received apparatus parameter data, controller42is programmed to determine whether to supply a current/voltage to external apparatus50to crank heat engine66in the external device50and/or to supply a current/voltage to external apparatus50to recharge energy storage system72(i.e., traction battery) in the external device50. Controller42determines a power requirement for the cranking/recharging operation and, responsive thereto, controls power converter40(i.e., controls cranking inverter44and/or charging boost converter46) to generate a conditioned power54that meets the determined power/voltage requirement. The conditioned power54can, for example, comprise an AC power output having a desired frequency suitable for providing cranking/recharging of the energy source56in external apparatus50. It is also recognized, however, that the conditioned power54can be in the form of a DC power output. As shown inFIG. 2, the conditioned power54generated by power converter40is passed through transfer switch48(which is in its “transfer mode” position) and electrical interface cable96to transfer switch92of external apparatus50, where it is then directed to one (or both) of the heat engine66and traction battery72to “jump-start” external apparatus50.

Referring now toFIG. 3, apparatus10is shown interfaced with an external apparatus100that is incorporated into an electric vehicle so as to provide recharging power thereto during the transfer mode of operation, according to another embodiment of the invention. That is, as shown inFIG. 3, apparatus includes an energy source102configured as an electric energy source that comprises an energy/traction battery104and a traction boost converter106. In an exemplary embodiment, energy battery104is in the form of a high voltage traction battery having an energy rating of 15 kWh or more. In operation, energy battery104provides power to traction boost converter106, which boosts and transfers the power to motor drive108.

External apparatus100includes a power converter110and a controller112configured to control operation of the power converter110. As shown inFIG. 3, power converter110is configured as a charging boost converter. A transfer switch114is also included in external apparatus100and is controlled by controller112to selectively couple the charging boost converter110to apparatus10. According to an embodiment of the invention, when it is desired to transfer power from apparatus10to external apparatus100, such as when traction battery104is depleted, controller42actuates or controls transfer switch48to electrically couple apparatus10to external apparatus100, so as to allow for transfer of conditioned power54therebetween.

Based on apparatus parameter data related to the external apparatus100received by controller42, such as battery voltage, battery rate, battery temperature, battery state-of-charge, and/or a vehicle make and model of the vehicle in which external apparatus100is incorporated, controller42determines a power requirement of the external apparatus100. That is, based on the received apparatus parameter data, controller42is programmed to determine an appropriate power to supply to external apparatus100to recharge energy storage system104(i.e., traction battery). Controller42determines a power requirement for the recharging operation and, responsive thereto, controls charging boost converter46to generate a conditioned power that meets the determined power/voltage requirement. The conditioned power can, for example, comprise an AC output having a desired frequency suitable for providing recharging of the energy traction battery in external apparatus100.

Referring now toFIG. 4, another embodiment of an apparatus120for producing tractive effort is shown. In this alternative embodiment, power converter122is fed from high DC voltage124instead of from low DC voltage126and may be used to charge power battery128. Power converter122may also be used to charge energy battery129through traction boost converter131. Also shown inFIG. 4, is the connection of apparatus120to one or more external apparatus130,140. That is, according to an embodiment of the invention, transfer switch132and controller134of apparatus120are configured to allow for transfer of conditioned power to more than one external apparatus130,140to provide power thereto. As shown inFIG. 4, transfer switch138of apparatus130allows for transfer of conditioned power to apparatus130, as well as interfacing to the additional apparatus140. Controller134of apparatus120is thus configured to receive apparatus parameter data on each external apparatus130,140to which apparatus120is electrically coupled, such as from controller136of external apparatus130and from controller(s) (not shown) of additional external apparatus140. Based on the received apparatus parameter data, controller134is programmed to determine a power requirement for each external apparatus130,140.

Referring now toFIG. 5, according to another embodiment of the invention, an apparatus142is configured as a plug-in hybrid vehicle. The plug-in hybrid vehicle142includes therein a power converter144having a cranking boost converter145and cranking inverter147. The plug-in hybrid vehicle142has a series hybrid configuration comprising an energy source146and a power battery151. The energy source146includes a heat engine148, an alternator149, and a traction boost converter153. It is recognized that traction boost converter153is coupled to a rectifier155on the low voltage side and could be implemented as a uni-directional or bi-directional boost converter, whereas the traction boost converters30,74,106,131ofFIGS. 1-4are bi-directional boost converters. As shown inFIG. 5, a transfer switch158is also included in plug-in hybrid vehicle142and is controlled by controller162to selectively couple the power converter144to components of the vehicle and/or an external apparatus154,156. The power converter144functions to recharge power battery (via cranking boost converter145) and/or crank heat engine148(via cranking inverter147and alternator149).

The plug-in hybrid vehicle142further includes a plug-in150that allows for connection of the vehicle to a utility grid. When vehicle142is not in operation (and the utility grid is operable), the plug-in150can be connected to a utility grid to receive AC power therefrom. The AC power from the utility grid is passed through an AC-DC charger interface152(i.e., a voltage and current controlled rectifier) to condition the power for transfer charging power battery151. The power received through plug in150from the utility grid is supplied to recharge the power battery151.

As shown inFIG. 5, plug-in hybrid vehicle142is connected to one or more external apparatus154,156by way of interfacing transfer switch158of vehicle142to a transfer switch160of external apparatus154. The controller162of plug-in hybrid vehicle142is configured to receive apparatus parameter data on each external apparatus154,156to which the vehicle is electrically coupled, such as from controller164of external apparatus154and from controller(s) (not shown) of additional external apparatus156. Based on the received apparatus parameter data, controller162is programmed to determine a power requirement for each external apparatus154,156.

While embodiments of the invention set forth above describe a charging of an external apparatus50,100,130,140,154,156by a charging apparatus10,120,142it is recognized that power transfer between the external apparatus and the charging apparatus may be bi-directional, and that the external apparatus50,100,130,140,154,156could be used to jump-start apparatus10,120,142. That is, as each apparatus includes an energy source, power converter, controller, and transfer switch, each apparatus is configured to provide a conditioned power to the other apparatus.

Also, while embodiments of the invention show the energy storage device in energy source as including only a single energy/traction battery, it is recognized that a plurality of batteries, battery arrangements, and or ultracapacitors could be used to form an energy storage device/system in electric or hybrid-electric energy sources.

Therefore, according to one embodiment of the invention, an apparatus includes an energy source configured to generate a power output, a power converter electrically connected to the energy source to receive the power output and to output a conditioned power, and a transfer switch configured to selectively couple the conditioned power to an external apparatus. The apparatus also includes a controller in communication with the external apparatus and configured to receive apparatus parameter data related to the external apparatus, determine a power requirement of the external apparatus based on the apparatus parameter data, operate the power convertor to output conditioned power that meets the power requirement of the external apparatus, and control the transfer switch to couple the conditioned power that meets the power requirement to the external apparatus.

According to another embodiment of the invention, a method for providing power to an external apparatus includes the step of interfacing a charging apparatus with the external apparatus, the charging apparatus comprising a energy source configured to generate a power output and a transfer switch configured to selectively electrically couple the charging apparatus to the external apparatus. The method also includes the steps of receiving apparatus parameter data on the external apparatus, determining a power requirement of the external apparatus based on the apparatus parameter data, controlling the transfer switch to electrically couple the charging apparatus to the external apparatus, and transferring power from the charging apparatus to the external apparatus at the determined power requirement.

According to yet another embodiment of the invention, a control system for controlling a supply of power from a vehicular energy source is programmed to receive apparatus parameter data of an external vehicular energy source and determine a power requirement of the external vehicular energy source based on the apparatus parameter data. The control system is further programmed to cause a power converter electrically connected to the vehicular energy source to generate conditioned power that meets the power requirement of the external vehicular energy source and actuate a transfer switch connected to the power converter source to electrically couple the power converter and the external vehicular energy source, thereby transferring the conditioned power from the power converter to the external vehicular energy source.