Portable plug-in electric vehicle alternating current power adapter and method of use

A portable alternating current (AC) power adapter system for a plug-in electric vehicle (PEV) having a high voltage (HV) battery system and configured for bi-directional charging includes a charging connector including a first 240 volts AC (VAC) signal circuit, a second 240 VAC signal circuit, a 120 VAC ground circuit, and a proximity circuit comprising a resistor, the proximity circuit being configured to wake-up the PEV when the charging cable is connected to the plug-in charging port, and a charging power panel electrically coupled to the charging connector and including a charge plug port connected to the first and second 240 VAC signal circuits and the 120 VAC ground circuit and configured to be connected to a 120 VAC or 240 VAC external load, and a switching relay connected to the proximity circuit and configured to transition on/off to disable/enable exporting power from the HV battery system.

FIELD

The present application generally relates to plug-in electric vehicles (PEVs) and, more particularly, to a portable PEV alternating current (AC) power adapter and its method of use.

BACKGROUND

A plug-in electric vehicle (PEV), such as a battery electric vehicle (BEV) or plug-in hybrid electric vehicle (PHEV), comprises a high-voltage (HV) battery system that is rechargeable via a plug-in charging port on the PEV. An owner/operator of the PEV connects EV supply equipment (EVSE) to the plug-in charging port for charging. This EVSE typically includes a charging cable connected to a charging station, which could be located at any suitable location such as their personal residence, their workplace, or in a public parking area. While connected to the EVSE, the PEV's HV battery system is recharged via high voltage alternating current (AC) power (e.g., 240 volts alternating current, or VAC). Conventional vehicle power adapter systems include in-vehicle plugs for providing 120 VAC power but not 240 VAC power, and also may require the vehicle to be running in order to operate. Accordingly, while such vehicle power adapter systems do work for their intended purpose, there exists an opportunity for improvement in the relevant art.

SUMMARY

According to one example aspect of the invention, a portable alternating current (AC) power adapter system for a plug-in electric vehicle (PEV) having a high voltage (HV) battery system and being configured for bi-directional charging is presented. In one exemplary implementation, the system comprises: a charging cable, a charging connector configured to connect to a plug-in charging port of the PEV, the charging connector including a first 240 volts AC (VAC) signal circuit, a second 240 VAC signal circuit, a 120 VAC ground circuit, and a proximity circuit comprising a resistor, the proximity circuit being configured to wake-up the PEV when the charging cable is connected to the plug-in charging port, a charging power panel electrically coupled to the charging connector via the charging cable and including a charge plug port connected to the first and second 240 VAC signal circuits and the 120 VAC ground circuit and configured to be connected to a 120 VAC or 240 VAC external load, and a switching relay connected to the proximity circuit and configured to transition on/off to disable/enable exporting power from the HV battery system of the PEV.

In some implementations, the charging connector further comprises a physical switch configured to be operated by a user to control the proximity circuit to control a state of the proximity circuit to connect/disconnect the charging connector to/from the plug-in charging port of the PEV. In some implementations, the charging power panel further comprises an indicator light indicative of a status of the charge plug port.

In some implementations, the 120 VAC ground circuit is configured to allow current to flow therethrough to accommodate for unbalanced power being carried through the first and second 240 VAC signal circuits. In some implementations, the first and second 240 VAC signal circuits and the 120 VAC ground circuit are all independent from each other.

In some implementations, the PEV is configured for bi-directional charging via two switching relays and a direct current (DC) to AC (DC-DC) converter of an on-board charging module (OBCM) of the PEV. In some implementations, the portable AC power adapter system is portable in that it can be disconnected and transported for use amongst a plurality of PEVs having a same-type of the plug-in charging port.

In some implementations, the charging power panel further comprises an AC to direct current (AC-DC) converter to step down power being carried through at least one of the first and second 240 VAC signal circuits to provide power to recharge an internal battery for initial power of the controls and if this internal battery is low of energy a universal serial bus (USB) port is connected to the vehicle port to recharge it and allow operation.

According to another example aspect of the invention, a PEV system is presented. In one exemplary implementation, the PEV system comprises a PEV including an electrified powertrain comprising an HV battery system, OBCM comprising two relays for providing bi-directional charging of/from the HV battery system, and a plug-in charge port comprising a first 240 VAC signal circuit, a second 240 VAC signal circuit, and a 120 VAC ground circuit, and a portable AC power adapter system configured to be selectively connected to the plug-in charge port for exporting power from the HV battery system of the PEV, the portable AC power adapter system including a charging cable, a charging connector comprising the first and second 240 VAC signal circuits, the 120 VAC ground circuit, and a proximity circuit comprising a resistor and being configured to wake-up the PEV when the charging cable is connected to the plug-in charging port, and a charging power panel electrically coupled to the charging connector via the charging cable and including a charge plug port connected to the first and second 240 VAC signal circuits and the 120 VAC ground circuit and configured to be connected to a 120 VAC or 240 VAC external load, and a switching relay connected to the proximity circuit and configured to transition on/off to disable/enable exporting power from the HV battery system of the PEV.

In some implementations, the charging connector further comprises a physical switch configured to be operated by a user to control the proximity circuit to control a state of the proximity circuit to connect/disconnect the charging connector to/from the plug-in charging port of the PEV. In some implementations, the charging power panel further comprises an indicator light indicative of a status of the charge plug port.

In some implementations, the 120 VAC ground circuit is configured to allow current to flow therethrough to accommodate for unbalanced power being carried through the first and second 240 VAC signal circuits. In some implementations, the first and second 240 VAC signal circuits and the 120 VAC ground circuit are all independent from each other.

In some implementations, the portable AC power adapter system is portable in that it can be disconnected and transported for use amongst a plurality of PEVs having a same-type of the plug-in charging port. In some implementations, the charging power panel further comprises an AC-DC converter to step down power being carried through at least one of the first and second 240 VAC signal circuits to provide power to recharge an internal battery for initial power of the controls and if this internal battery is low of energy a USB port is connected to the vehicle port to recharge it and allow operation.

Further areas of applicability of the teachings of the present application will become apparent from the detailed description, claims and the drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be understood that the detailed description, including disclosed embodiments and drawings referenced therein, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the present application, its application or uses. Thus, variations that do not depart from the gist of the present application are intended to be within the scope of the present application.

DESCRIPTION

As previously discussed, conventional vehicle power adapter systems include in-vehicle plugs for providing 120 volts alternating current (VAC) power but not 240 VAC power, and these systems may also may require the vehicle to be running in order to operate. Accordingly, a portable AC power adapter system for a PEV is presented. The portable AC power adapter system is configured to be selectively connected to a plug-in charge port of the PEV for exporting power from its high voltage (HV) battery system.

The portable AC power adapter system includes a charging cable, a charging connector comprising the first and second 240 VAC signal circuits, the 120 VAC ground circuit, and a proximity circuit comprising a resistor and being configured to wake-up the PEV when the charging cable is connected to the plug-in charging port, and a charging power panel electrically coupled to the charging connector via the charging cable and including a charge plug port connected to the first and second 240 VAC signal circuits and the 120 VAC ground circuit and configured to be connected to a 120 VAC or 240 VAC external load, and a switching relay connected to the proximity circuit and configured to transition on/off to disable/enable exporting power from the HV battery system of the PEV. While EV charging in compliance with the Society of Automotive Engineers (SAE) J1172 standard is generally described herein, it will be appreciated that these techniques could be applicable to other suitable charging standards.

Referring now toFIGS.1and2A-2B, a functional block diagram of an example PEV system100and circuit diagrams200a,200bof one example configuration of the PEV system100according to the principles of the present application are illustrated. The PEV system100comprises a PEV104(a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV), etc.) having an electrified powertrain108comprising a HV battery system112and one or more electric traction motors116for propulsion of the PEV104. The PEV104further includes an on-board charging module (OBCM)120connected to a plug-in charge port (PCP)124. The OBCM120comprises two relays (R1, K1)128,132for providing bi-directional charging of/from the HV battery system112using one or more AC/DC converters136and a controls circuit for controlling recharging/off-load charging. The plug-in charge port124comprises a first 240 volts AC (VAC) signal circuit140, a second 240 VAC signal circuit144, and a 120 VAC ground circuit148. The OBCM120further comprises other circuits and components including, but not limited to, resistors R2(e.g., ˜1.3 kiloohms (kΩ)), R3(e.g., ˜2.74 kΩ), R4(e.g., ˜330Ω), and R5(e.g., ˜2.7 kΩ), a diode, a switch S2, and a low voltage source V (e.g., ˜5 V). The PCP124comprises the initial resistor R5(e.g., ˜2.7 kΩ) that needs to be disconnected from the 120 VAC ground circuit148for this application, since this is now part of the OBCM. The PEV system100further comprises a portable AC power adapter system152according to the principles of the present application.

The portable AC power adapter system152is portable in that it can be disconnected and transported for use amongst a plurality of PEVs having a same-type of the plug-in charging port (i.e., a same type as plug-in charge port124). The portable AC power adapter system152generally comprises a charging cable156electrically connected between a charging connector160and a charging power panel164. The charging connector160is configured to be selectively connected to the plug-in charge port124of the PEV104. The charging connector160includes the first and second 240 VAC signal circuits140,144and the 120 VAC ground circuit148. These three circuits140,144,148are all independent of each other at least for purposes of the charging connector160.

The charging connector160further comprises a proximity circuit168comprising resistors R6(e.g., ˜150Ω), R7(e.g., ˜330Ω), relay S3(e.g., normally closed), and an optional physical switch172that needs to be disconnected from the 120 VAC ground circuit148for this application since it now connects to Relay R1184. The proximity circuit168is configured to, upon connection of the charging connector160to the plug-in charge port124, wakeup the PEV104for power exporting (similar to wake-up the PEV for recharging). This can include, for example, configuring the two relays R1128, K1132to enable power exportation (i.e., DC-to-AC conversion and exportation. In one example implementation, the physical switch172(shown as S3) is configured to be operated by a user to control the proximity circuit168to control a state of the proximity circuit168to connect/disconnect the charging connector160to/from the plug-in charging port124of the PEV104.

The charging power panel164comprises an indicator light176indicative of a status of a charge plug port180connected to the first and second 240 VAC signal circuits140,144and the 120 VAC ground circuit148(via the charging cable156) and with two fuses F1(e.g., ˜40 amps, or A) and F2(e.g., ˜40 A) thereabout. The 120 VAC ground circuit148, for example, could be configured to allow current to flow therethrough to accommodate for unbalanced power being carried through the first and second 240 VAC signal circuits140,148. This would normally not occur or otherwise be necessary during balanced PEV recharging. The charging power panel164further comprises a switching relay R1184connected to the proximity circuit168(via the charging cable156) and configured to transition on/off to disable/enable exporting power from the HV battery system112of the PEV104.

In one example implementation, the charging power panel164further comprises an AC-DC converter188to step down power being carried through at least one of the first and second 240 VAC signal circuits to provide power to recharge an internal battery (+/−) used to initiate the V2L controls. If this internal battery is not able to power the controls due to extended storage times, a universal serial bus (USB) port192(e.g., is used for initial power of the panel control circuit196). This control circuit196controls operation of the charging power panel196, e.g., via resistor R8(e.g., ˜1 kΩ) and an oscillator (e.g., a 4 kilohertz (kHz) pulse-width modulation (PWM) signal generator) identifying to the vehicle that the power panel is connected and ready to use. The charging power panel164further comprises other circuits and components including, but not limited to, the internal battery, a switch S1, and an ON light as shown.

The proximity circuit168is generated from the vehicle100and the pilot196is normally generated from the EVSE for charging. The both normally use the ground circuit148for return; however, with the 240V power panel164the ground is a current carrying conductor as are the two circuits140and144. The relays R1184and R1128switch the proximity circuit168and pilot196to use each other as the return circuit while K1132switches the ground from charging to power panel modes.

Referring now toFIG.3, a method300of operating a portable AC power adapter system according to the principles of the present disclosure. While the specific configuration200a,200bof the portable AC power adapter and the PEV104are specifically referenced, it will be appreciated that this method300could be applicable to slightly different configurations of the PEV104and/or the portable AC power adapter152. At optional304, the user actuates the optional physical switch172on the charging connector160. At308, the user plugs the charging connector160into the plug-in charging port124of the PEV104. At312, it is determined whether a proper connection has been made. This could include the PEV104waking up and being prepared to off-load AC power via the portable AC power adapter152.

Preconditions could include, for example only, a secure physical connection and a state of charge (SOC) of the HV battery system112at an appropriate level (i.e., high enough) for AC power exportation. When false, the method300ends or returns to308. When true, the method300proceeds to316where the charging power panel164illuminates the light176indicating that AC power exportation via plug180is ready. The user could also then release the physical switch172on the charging connector160. At320, AC power exportation occurs via the plug180and/or the USB port192(DC converted AC power).

At324, it is determined whether an exit condition has occurred. This could include, for example only, the user depressing the physical switch172to actuate the proximity circuit168and interrupt/stop charge off-loading. This could also include, for example, the SOC of the HV battery system112falling below a threshold level. In other words, charge off-loading should not occur past a certain point in order to not strand the PEV104somewhere without sufficient charge to power the electrified powertrain108. When false, the method300returns to320and charge off-loading continues. When true, however, the method300proceeds to328where the indicator light176is turned off indicating that AC power is no longer available at the plug180of the charging power panel164and then at332the user safely unplugs the charging connector160from the plug-in charge port124and the method300ends or returns to304for another possible cycle.

It will be appreciated that the term “controller” as used herein refers to any suitable control device or set of multiple control devices that is/are configured to perform at least a portion of the techniques of the present application. Non-limiting examples include an application-specific integrated circuit (ASIC), one or more processors and a non-transitory memory having instructions stored thereon that, when executed by the one or more processors, cause the controller to perform a set of operations corresponding to at least a portion of the techniques of the present application. The one or more processors could be either a single processor or two or more processors operating in a parallel or distributed architecture.