Abstract:
A DC/DC power converter includes an electrically configurable transformer/inductor. The electrically configurable transformer/inductor receives a power plug. The power plug, depending on its configuration, configures the operation of the transformer/inductor and therefore the DC/DC power converter. The power plug may permit access to power received from the power converter. The power plug may also pass power to the power converter from a remote electrical source.

Description:
BACKGROUND 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to power converter systems for automotive vehicles and methods for configuring the same. 
         [0003]    2. Discussion 
         [0004]    An alternatively powered vehicle may include an energy storage unit, e.g., battery. A DC/DC power converter may be used to convert power from the energy storage unit for use, for example, by a motor of the alternatively powered vehicle. As such, power from the energy storage unit may be used to move the vehicle. 
       SUMMARY 
       [0005]    Embodiments of the invention may take the form of a power converter system for an automotive vehicle. The system includes a power converter for receiving power at a first voltage and presenting power at a second voltage. The power converter includes an electrically configurable transformer for receiving a removable electrical plug. The plug, when received, electrically configures the transformer. 
         [0006]    Embodiments of the invention may take the form of a removable electrical plug system for a vehicle power converter including an electrically configurable transformer. The system includes a removable electrical plug for configuring the electrical operation of the transformer. The plug includes electrical contacts for electrically connecting the plug with the transformer, for electrically configuring the transformer, and for enabling the power converter to enter an active state. 
         [0007]    Embodiments of the invention may take the form of a method for electrically configuring a power converter system for an automotive vehicle. The method includes providing a power converter configured to receive power at a first voltage and present power at a second voltage. The power converter includes an electrically configurable transformer for receiving a removable electrical plug. The method also includes providing a removable electrical plug for configuring the electrical operation of the electrically configurable transformer. The method further includes electrically connecting the removable electrical plug with the electrically configurable transformer. 
         [0008]    While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a schematic diagram of a portion of an example power distribution system for an automotive vehicle including a DC/DC power converter. 
           [0010]      FIG. 2  is a schematic diagram of an example transformer of the DC/DC power converter of  FIG. 1 . 
           [0011]      FIG. 3  is a schematic diagram of an example power plug that may be used with the transformer of  FIG. 2 . 
           [0012]      FIG. 4  is a schematic diagram of the transformer and power plug of  FIGS. 2 and 3  respectively. 
           [0013]      FIG. 5  is a schematic diagram of a portion of another example transformer of the DC/DC power converter of  FIG. 1  and a portion of another example power plug that may be used with the transformer. 
           [0014]      FIG. 6  is a schematic diagram of another example transformer of  FIG. 1  and another example power plug that may be used with the transformer. 
           [0015]      FIG. 7  is a schematic diagram of yet another example transformer of  FIG. 1  and yet another example power plug that may be used with the transformer. 
           [0016]      FIG. 8  is a schematic diagram of the transformer of  FIG. 7  and still another example power plug that may be used with the transformer. 
           [0017]      FIG. 9  is a schematic diagram of still yet another example transformer of  FIG. 1  and still yet another example power plug that may be used with the transformer. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    A power converter, e.g., high power DC/DC converter, of an alternatively powered vehicle, e.g., a hybrid electric vehicle (HEV), may be configured for multiple applications. For example, isolated output power may be extracted from the DC/DC converter and processed by another on-board or off-board/portable converter to yield a 50/60 Hz AC output for a wide range of applications, e.g., residential power. 
         [0019]    Some converter topologies, e.g., bi-directional DC/DC converter topologies, shuffle power between an input and an output. If an inductor of a converter is replaced by a transformer with one or more isolated secondary windings, the converter may also provide isolated output power. This isolated power may be converted to, for example, 50/60 Hz AC by an additional power converter. 
         [0020]    Primary and secondary windings of some transformers may be connected in parallel or in series. This may increase component utilization and may improve system performance. Connecting the primary and secondary windings in parallel, if they have the same number of turns, may increase the current rating of the converter and/or reduce inductor copper loss. Connecting the primary and second windings in series may increase the inductance of the choke which may decrease ripple current and iron loss. 
         [0021]    If secondary windings of a power converter serve dual functions, a controller may cease operation of the converter before the converter is reconfigured. Interlocks may be incorporated in a power connector, e.g., plug, which permit access to power from the converter. Some interlocks may be designed so that they are disconnected prior to any main connections. 
         [0022]    Universal plug housings may be designed such that different interconnections may be installed on different sides, orientations, angles, locations, etc., of the plug housing. As such, the function of a power converter may depend on how the plug is inserted. For example, a plug may be configured such that if it is inserted one way, primary and secondary windings of a transformer of the converter are connected in parallel and if it is inserted another way, the primary and secondary windings are connected in series. Other configurations are also contemplated. For example, a plug may include interconnections that determine a desired output voltage or numbers of outputs, etc. 
         [0023]      FIG. 1  is a schematic diagram of power system  10  of vehicle  12 . Power system  10  includes high voltage battery  14 , motor drives  16 ,  18 , and DC/DC power converter  20 . Battery  14  is electrically connected with motor drives  16 ,  18  via power converter  20 . In other embodiments, other loads and sources, e.g., fewer motor drives, additional batteries, etc., may be electrically connected with power converter  20 . 
         [0024]    Power converter  20  of  FIG. 1  includes inductor/transformer  22 , switches  24 ,  26 , and capacitors  25 ,  27 . By selectively switching switches  24 ,  26 , power converter  20  may, for example, receive power, e.g., V x , from battery  14  and boost it to, for example, V y  for use by motor drives  16 ,  18 . Power converter  20  may also receive power from motor drives  16 ,  18 , e.g., V y , and buck it to, for example V x  for subsequent storage by battery  14 . Table 1 summaries example values that V x , V y , and V m  may achieve: 
         [0000]                            TABLE 1               V x  (volts)   V y  (volts)   V m  (volts)                   300   300-500   0-V y                      
In other embodiments, power converter  20  may take on other topologies such that, for example, it behaves as a uni-direction boost converter, etc.
 
         [0025]      FIG. 2  is a schematic diagram of an embodiment of inductor/transformer  22 . Inductor/transformer  22  of  FIG. 2  includes primary coil  28  and secondary coil  30 . Primary coil  28  of  FIG. 2  includes terminals  31 ,  33 . Terminals  31 ,  33  may be electrically connected with V x  and V m  respectively via prongs  32 ,  34  ( FIG. 3 ) respectively of power plug  35  ( FIG. 3 ). Secondary coil  30  of  FIG. 2  includes terminals  36 ,  38 . Terminals  36 ,  38  may also be electrically connected with prongs  32 ,  34  of power plug  35 . In other embodiments, inductor/transformer  22  may have more than two terminals, e.g., 6, etc., depending on design requirements. In the absence of power plug  35 , power converter  20  would remain inactive as V x  and V m  would not be electrically connected. 
         [0026]    Interlock terminals  40 ,  42  are electrically connected with controller  43  ( FIG. 4 ). Interlock terminals  40 ,  42  may be electrically connected with interlock conductors  44 ,  46  ( FIG. 3 ) of power plug  35  ( FIG. 3 ). As discussed below, this electrical connection may facilitate communication with controller  43 . 
         [0027]      FIG. 3  is a schematic diagram of power plug  35 . Prong  32  includes electrical conductors  48 ,  50  and prong  34  includes electrical conductors  52 ,  54 . Electrical conductors  50 ,  54  are electrically connected with power leads  56 ,  58  respectively. Power leads  56 ,  58  permit, for example, electrical devices, e.g., a power tool, to access power subsequently from battery  14  ( FIG. 1 ) via power converter  20  ( FIG. 1 ) and power plug  35 . Power leads  56 ,  58  also permit, for example, electrical power sources to store energy in battery  14  via power plug  35  and converter  20 . 
         [0028]    Interlock conductors  44 ,  46  are electrically connected with interlock leads  60 ,  62 . As discussed below, this electrical connection may facilitate communication with controller  43 . 
         [0029]      FIG. 4  is a schematic diagram of power plug  35  plugged with inductor/transformer  22 . When plugged, electrical conductors  48 ,  52  electrically connect terminals  31 ,  33  of primary coil  28  with V x  and V m  respectively. Electrical conductors  50 ,  54  electrically connect terminals  36 ,  38  with power leads  56 ,  58  respectively. As such, power leads  56 ,  58  provide power that is, for example, galvanically isolated from battery  14  ( FIG. 1 ). 
         [0030]    Interlock conductors  44 ,  46  electrically connect controller  43  with interlock leads  60 ,  62 . In alternative embodiments, some number of interlock leads other than two, e.g., four, may be provided. In the embodiment of  FIG. 4 , electrical devices may communicate with controller  43  via this electrical connection. For example, communication signals may be sent from controller  43  to an electrical device through interlock terminals  40 ,  42 , interlock conductors  44 ,  46 , and interlock leads  60 ,  62 . Likewise, communication signals may be sent from an electrical device to controller  43  via interlock leads  60 ,  62 , interlock conductors  44 ,  46 , and interlock terminals  40 ,  42 . In other embodiments, such communication may take place via optics, e.g., fiber optics, infrared, etc., or via non-contact electromagnetics. 
         [0031]      FIG. 5  is a schematic diagram of a portion of inductor/transformer  122  and power plug  135 . Numbered elements differing by factors of  100  have similar, although not necessarily identical, descriptions, e.g., controller  43 ,  143 . Coil  164  spans interlock terminals  140 ,  142 . Coil  166  spans interlock conductors  144 ,  146 . Electrical signals sent through coil  164  from controller  143  induce electrical signals through coil  166 . Likewise, electrical signals sent through coil  166  from, for example, an electrical device, induce electrical signals through coil  164 . 
         [0032]      FIG. 6  is a schematic diagram of inductor/transformer  222  and power plug  235 . Electrical conductor  264  electrically connects primary coil  228  with V x  and power lead  256 . Electrical conductor  254  electrically connects power lead  258  with common terminal  266 , e.g., ground. As such, power leads  256 ,  258  provide power that is, for example, not isolated from battery  214  (not shown). 
         [0033]      FIG. 7  is a schematic diagram of inductor/transformer  322  and power plug  335 . Electrical conductors  368 ,  370  electrically connect primary coil  328  in parallel with secondary coil  330 . 
         [0034]    Power plug  335  includes electronic tag  372 , e.g., a resistor having a predetermined resistance, a capacitor having a predetermined capacitance, etc. Controller  343  may determine which type of power plug is plugged with inductor/transformer  322  by, for example, sending a signal though interlock terminals  340 ,  342 , and interlock conductors  344 ,  346  and measuring the change in voltage of the signal received. For example, power plug  135  ( FIG. 4 ) may have an electronic tag (not shown) that results in, for example, a 1 V drop in voltage. Power plug  235  ( FIG. 6 ) may have electronic tag (not shown) that results in, for example, a 2 V drop in voltage. 
         [0035]      FIG. 8  is a schematic diagram of inductor/transformer  322  and power plug  435 . Electrical conductors  374 ,  376 ,  378 ,  380  electrically connect primary coil  328  in series with secondary coil  330 . Electronic tag  472  includes an active circuit that may, for example, produce a series of pulsed signals in response to a power/signal sent by controller  343 . 
         [0036]      FIG. 9  is a schematic diagram of inductor/transformer  522  and power plug  535 . Electrical conductors  568 ,  570  electrically connect primary coil  528  in parallel with secondary coil  530 . Prong  584  includes electrical conductor  586 . Power lead  556  is electrically connected with terminal  582  via electrical conductor  586 . Power lead  558  is electrically connected with terminals  533 ,  538  via electrical conductor  570 . Power lead  559  is electrically connected with terminals  531 ,  536  via electrical conductor  568 . As such, power leads  556 ,  558 ,  559  provide AC power that is not isolated from battery  514  (not shown). 
         [0037]    While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.