Patent Publication Number: US-2023139177-A1

Title: Three-phase synchronous rectifier for charging a battery on board the vehicle

Description:
TECHNICAL FIELD 
     The present invention relates to a three-phase synchronous rectifier for charging a battery on board the vehicle. 
     BACKGROUND ART 
     The increasing need for high power on board vehicles has led to the development of systems for the production of electrical energy currently able to deliver currents of over 120 A with nominal voltages of about 12V. 
     In the case of special motor applications such as, e.g., ATVs (All-Terrain Vehicles) or snowmobiles, these systems are generally made by connecting a three-phase AC generator with permanent magnets, which converts the mechanical power of the endothermic engine into electrical power, to a voltage regulator that rectifies the three-phase alternating current coming out of the generator to supply the vehicle battery to which the various vehicle charges are connected, with a rectified direct voltage kept constant at a value of 14.5V. 
     It should also be specified that in the vehicles listed above, conventional automotive-type generators and regulators cannot be used due to space constraints. A typical solution for regulating such high currents using compact devices involves, in fact, separating the three-phase outputs downstream of the AC generator wherein each output is connected to an individual voltage regulator. The use of two separate outputs makes it possible, as far as possible, to limit the electrical current circulating in the individual connection through the use of small regulators. 
     It has however been noted that the use of two separate regulators does not allow the same level of regulation voltage and inevitably the currents in the two three-phase branches at the input and output of the regulators will be unbalanced. It follows that this unbalance will produce a reduction in the total efficiency of the electrical energy generation system as well as any possible vibrations due to the misalignment of the forces operating between the rotor and stator of the permanent magnet generator. 
     DESCRIPTION OF THE INVENTION 
     In view of the problems set out above, the main aim of the present invention is to devise a three-phase synchronous rectifier for charging a battery on board the vehicle that allows the individual currents at the output from the two three-phase windings of the AC generator to be managed and kept balanced by means of an individual compact regulating unit and capable of simultaneously regulating current values even beyond 150 A. 
     Another object of the present invention is to devise a three-phase synchronous rectifier which allows battery protection in case of disconnections and/or wrong polarity connections or in case of short circuits at the output of the regulating unit. 
     Another object of the present invention is to devise a three-phase synchronous rectifier which allows to overcome the mentioned drawbacks of the prior art within a simple, rational, easy, effective to use and affordable solution. 
     The above mentioned objects are achieved by the present three-phase synchronous rectifier for charging a battery on board the vehicle according to the characteristics described in claim  1 . 
     A further object of the present invention is to devise a three-phase synchronous rectifier system according to claim  15 . 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other characteristics and advantages of the present invention will become more evident from the description of a preferred, but not exclusive, embodiment of a three-phase synchronous rectifier for charging a battery on board the vehicle, illustrated by way of an indicative, yet non-limiting example, in the accompanying tables of drawings wherein: 
         FIG.  1    shows a three-phase synchronous rectifier, usable in conjunction with a generator to charge a vehicle battery according to the invention; 
         FIGS.  2  and  3    show the circuit diagrams of the rectifier in  FIG.  1   ; 
         FIG.  4    is a graph illustrating the trend of the output signal on the positive terminal in the case of disconnected battery; 
         FIGS.  5  and  6    show, respectively, the graphs in the case of in-phase and out-of-phase connection of the generator windings. 
     
    
    
     EMBODIMENTS OF THE INVENTION 
     With particular reference to these figures, a three-phase synchronous rectifier has been globally referred to as RT, which can be used in particular in conjunction with a generator G for charging a battery B of a motor vehicle. 
     In detail, the three-phase synchronous rectifier RT comprises a rectification circuitry  1  installed inside an enclosure  2  wherein a first and a second input  3 ,  4  independent of each other and each connectable to respective three-phase output branches  5 ,  6  of the generator G are identified. The rectifier RT is also provided with two negative and positive outputs  7 ,  8  also independent and each connectable to the respective poles of the battery  9 ,  10 . 
     Conveniently, the inputs  3 ,  4  of the rectifier RT are made by means of respective three-pole female input connectors  11 ,  12  positioned at a same input side  13  of the enclosure  2 . Similarly, the outputs  7 ,  8  are made by means of respective three-pole female output connectors  14 ,  15  positioned at a same output side  16  opposite the input side  13  of the enclosure  2 . 
     As shown in the example of  FIG.  1   , the battery B can be connected downstream of the rectifier RT while the generator G can be connected upstream of the rectifier RT. To this end, the connection between the generator G and the rectifier RT can be made by means of two separate and independent upstream wiring harnesses  17 ,  18 , each ending with a respective three-pole male connector  19 ,  20  intended to be inserted respectively into the three-pole female input connectors  11 ,  12  of the rectifier RT. 
     Preferably, the three-pole female input connectors  11 ,  12  of the rectifier RT are identical to each other and can indifferently receive any of the two three-pole male connectors  19 ,  20  of the wiring harnesses  17 ,  18 . 
     According to an embodiment, the generator G is preferably a three-phase permanent magnet alternating current generator of the stator/rotor type in which to the stator  21  are operationally connected the two wiring harnesses  17 ,  18  to the three-phase output branches  5 ,  6 . 
     Preferably, the stator  21  of the generator G comprises twenty-four slots with double layer winding coupled to a rotor  22  having sixteen rare earth magnets, arranged in an alternating N-S or Halbach array configuration. Conveniently, each phase of the first output branch  5  and of the second output branch  6  of the generator G is connected with four stator coils of the stator  21  in parallel with each other. 
     Conveniently, the connection between the rectifier RT and the battery B can be made by means of two separate and independent downstream wiring harnesses  23 ,  24 , each ending with a respective male connector  25 ,  26  intended to be inserted into the connectors  14 ,  15  of the rectifier RT. 
     Preferably, each three-pole female output connector  14 ,  15  of the rectifier RT is operationally connected to a respective negative and positive output of the rectifier RT. To this end, the output connectors  14 ,  15  of the rectifier RT are different from each other to avoid any possible misconnections between the battery B and the rectifier RT. Substantially, each male connector  25 ,  26  of the downstream wiring harnesses  23 ,  24  may be operationally connected to only one of the negative and positive outputs of the rectifier RT. 
     Advantageously, as can be seen in the magnifying views of  FIG.  1   , also the male connectors  19 ,  20  of the upstream wiring harnesses  17 ,  18  are of the three-pole type, having to be coupled to the respective three-phase output branches  5  and  6  of the generator G. Since the generator G consists of a stator with two three-phase windings identical to each other and since the rectifier RT has an individual control signal exiting A and common to all the rectification units U A , U B , U C , U A′ , U B′ , U C′ , it follows that the currents of the phases I A , I B , I C , I A′ , I B′ , I C′ involving the terminals of the two three-phase connectors are equal to each other. As an example, it has been found that this solution allows keeping the currents around 50 A rms  per individual terminal of the connectors if the total current to be sent to the battery B is equal to about 150 A. In order to divide the output currents of the rectifier RT, the output connectors  14  for the negative pole and  15  for the positive pole have the three terminals of each connected in parallel internally to the rectifier so that the current I BATT S is I BATT S/3 on each of the 3 positive and negative terminals. More precisely in the case of 150 A DC  at the output from the rectifier RT, each terminal of the negative and positive connectors  14  and  15  will have a current of 50 A rms  flowing through it, while the terminals of the two three-phase connectors will have a current of about 53 A rms  flowing through them. 
     As shown in the example of  FIG.  2   , the rectifier RT has a first group consisting of three rectification units U A , U B , U C  each in signal communication with the respective phases of the first output branch  5  of the generator G and a second group of three rectification units U A′ , U B′ , U C′ each in signal communication with the respective phases of the second output branch  6  of the generator G. 
     Advantageously, the rectification units U A , U B , U C  and U A′ , U B′ , U C′ are configured to receive at input respective phase currents I A , I B , I C  and I A′ , I B′ , I C′ from the generator G and to supply at output an individual total rectified current I BATT S to be sent to the battery B of the vehicle. In detail, the total current I BATT S is made up of the sum of the individual rectified currents I BATT A, I BATT B, I BATT C, I BATT A′, I BATT B′, I BATT C′. 
     It should be noted that the operation of each of the rectification units U A , U B , U C  and U A′ , U B′ , U C′ , the current limiting circuit A intended to limit the current supplied by the generator G to the battery B in the event of the supplied voltage V Batt  exceeding a predefined value, as well as the operation of the two embodiments of the sensor S, are entirely similar to what described in the disclosure WO 2019/171320 A1 of the Applicant incorporated herein by way of reference. 
     With reference to the example illustrated in  FIG.  3   , the power supply of the electronic circuitry inside the rectifier RT is carried out by means of a power supply unit P operationally connected to the respective phases of the generator G by simultaneous connection to the two output branches  5 ,  6 . In detail, the power supply unit P comprises a voltage stabilizer U 7 , known in itself, connected to the six diodes D 7 ÷D 12 , wherein each anode of each diode is connected to one of the phases of the generator G and the respective cathodes, in common with each other, are connected to an electrolytic capacitor C 5 . The capacitor C 5  is connected in turn to the input of the voltage stabilizer U 7 , a second terminal connected to the internal negative pole of the regulator while the output, connected to the capacitor C 8 , provides the stabilized voltage V CC  to supply the electronic circuitry inside the rectifier RT. 
     According to some embodiments of the invention, the rectifier RT may have a plurality of devices to prevent irreparable damage to the control circuitry  1 . In the present case, the Applicant has implemented several protection solutions in the event of:
         possible disconnections of the battery B,   wrong connection of the polarities of the battery B,   permanent short circuit at the output of the rectifier RT.       

     In this context, as illustrated in the example of  FIGS.  2  and  3   , the rectifier RT may comprise a limitation block K operationally connected to the current limiting circuit A to limit the maximum output voltage of the rectifier RT in case of a disconnection of the battery B in order to safeguard the charges connected to the vehicle electrical system from any damage caused by over-voltages. In particular, the zener diode D 21  of the limitation block K is connected with the anode to the capacitor C 4  and with the cathode to the capacitor C 5 , where the voltage V GEN  is present. Preferably, the voltage of the zener diode D 21  is chosen at a value comprised between 18 and 21 volts. 
     According to a first operating configuration, that is when the rectifier RT is normally connected to the battery B, the capacitor C 5  is charged at a voltage close to the predefined operating voltage of the battery B, equal to about 14.5 Volts, through the six diodes D 7 ÷D 12 . As the voltage of the zener diode D 21  is higher than this predefined value, e.g. 21 Volts, there will be no current flow from C 5  to C 4  through the zener diode D 21  and therefore the regulation voltage on the battery B will not be modified and the rectifier RT will operate normally. According to a second operating configuration, in case of disconnection of the battery B, the total current I BATT S that is circulating from the generator G to the battery B through the Power MOS Q 1 , Q 2 , Q 6 , Q 7 , Q 8 , Q 9 , Q 10 , Q 11 , Q 12 , Q 13 , Q 14  and Q 15 , as well as the protection ones against battery connection inversion Q 22 , Q 23  and Q 24 , is suddenly interrupted and consequently passes to charge the capacitor C 5  through the six diodes D 7 ÷D 12 . The voltage V GEN  on the capacitor C 5  will rapidly increase until it reaches the voltage of the zener diode D 21  thus allowing the charging of the filter capacitor C 4 . At this point the rectifier RT switches from controlling the voltage of the battery B to controlling the voltage on the capacitor C 5  which results to be the sum of the voltage of the zener D 21  plus the one resulting from the following relation: 
       ( R 28+ R 30)/ R 30×0.6
 
     where 0.6 volts represents the drop of the diode D 6 . 
     With the battery disconnected, at the output of the rectifier RT on the positive terminal V Batt  there will be voltage pulses limited to a voltage of about 23 Volts which also represents the voltage value V C5  at which the capacitor C 5  is charged through the six diodes D 7 , D 8 , D 9 , D 10 , D 11 , D 12  as shown in the graph in  FIG.  4   . 
     According to one embodiment, the rectifier RT may be configured to verify any wrong polarity connections of the battery B and/or possible short circuits. In this case, as shown in the example of  FIGS.  2  and  3   , the rectifier RT comprises a verification circuitry H having a control block L connected to a first memory MEM 1  and to a second memory MEM 2 . 
     The control block L is provided with a plurality of N-channel Power MOS Q 22 , Q 23  and Q 24  with the drains and sources in parallel with each other and respectively connected to the negative pole of the battery B (shown in  FIG.  3    with the symbol Gnd Power) and to the internal negative pole of the rectifier RT (shown in  FIG.  2    with the ground symbol). Preferably, the number of Power MOS to be connected in parallel depends on the maximum current of the rectifier RT being crossed by the entire charging current of the battery B, I BATT S. 
     Three zener diodes D 17 , D 18  and D 19  are connected between each gate of the three Power MOS Q 22 , Q 23  and Q 24  and their respective sources in order to limit the maximum voltage applied to the gate. The Power MOS Q 22 , Q 23  and Q 24  are further connected by means of the three resistors R 37 , R 38  and R 39  to the interconnected emitters of the pair of transistors Q 20  and Q 21 , in NPN and PNP configuration respectively, connected with the bases in common. In this way, the transistors Q 20  and Q 21  are able to deliver high peak currents in order to quickly drive the Power MOS Q 22 , Q 23  and Q 24  in conduction or in interdiction. 
     Conveniently, the control block L also comprises NPN transistors Q 25 , Q 26 , and Q 27  with the emitters in common and connected to the internal negative terminal of the rectifier RT. As observable, the collector of the transistor Q 21  is also connected to the internal negative terminal of the rectifier RT. 
     The operational connection between the control block L and the memories MEM 1  and MEM 2  is made as explained below: the collector of Q 25  is connected to the bases of Q 20  and Q 21  and to the output OUT 2  of the memory MEM 2  by means of R 36 ; the collector of Q 26  is connected to the base of Q 25  and to the terminal V GEN  representing the voltage at which the capacitor C 5  is charged, by means of the resistor R 33 ; the collector of Q 27  is connected to the base of Q 26  and to the output OUT 2  of MEM 2  through the resistor R 34 ; the base of Q 27  is connected to the bias resistor R 42  and to the output OUT 1  of MEM 1  through the resistor R 27 . 
     Preferably, the zener diode D 22 , connected between the collector and the base of Q 21  with the anode on the collector, allows limiting the driving voltage applied to the gates of Q 22 , Q 23 , Q 24  at a lower value than the maximum value allowed by the devices. 
     With reference to the memory MEM 1 , on the contrary, the latter is provided with two transistors Q 16 , Q 18 , PNP and NPN respectively, connected together in positive reaction through the resistors R 21 , R 23 , R 24 , R 31 . The collector of Q 16  is connected to the resistor R 27  of the control block L by means of the output OUT 1 . 
     As visible in  FIG.  3   , the memory MEM 1  is operationally connected to an optoisolator J 1  in order to control or not the flow of current I BATT S between the control block L and the battery B, while maintaining the electrical insulation between them. In this case, the collector and the emitter of Q 18  are connected respectively to the collector and to the emitter of the transistor of the optoisolator J 1  which is also connected to the internal negative terminal of the regulator. Additionally, the anode of the diode of the optoisolator J 1  is connected to the negative terminal of the battery B and to the positive terminal of the battery B through the resistor R 29  and the diode D 15  the cathode of which is also connected to the positive terminal of the battery B. Advantageously, this type of configuration allows the flow of current in the diode of the optoisolator J 1  only in the case where the battery B is connected to the positive terminal to Gnd Power, i.e. connected with inverted polarity. In this configuration, the transistor of the optoisolator J 1  starts conduction and causes the chain conduction of the transistors Q 16  and Q 18  thus bringing the output OUT 1  of the memory MEM 1  to the logic level 1 corresponding to the voltage V GEN . The logic level 1 of the memory MEM 1  thus remains as long as the capacitor C 5  remains charged, that is, as long as the generator G is rotating, even if the battery B is disconnected from the rectifier RT. The passage of the memory MEM 1  to the logic value 0, i.e. with the output OUT 1  at 0 Volt, can only occur when the voltage V GEN  is zeroed, i.e. when the generator G is not moving. 
     Looking again at the memory MEM 2  in the  FIG.  3   , it is necessary to specify that the latter substantially works as a hysteresis comparator where the two transistors Q 28  and Q 29  are commanded in simultaneous conduction when the voltage V GEN  exceeds the value of the voltage of the zener diode D 20  added to that determined by the resistive divider R 43 -R 45  on the basis of the transistor Q 29 . As an example, this voltage can be chosen at a value of about 12 Volts. Since Q 28  is in conduction also the output OUT 2  of MEM 2  will be at the logic level 1, that is until the voltage value V GEN  will not fall to a value lower than the voltage determined by the voltage of the zener diode D 16  added to that determined by the resistive divider R 44 -R 35  on the basis of the transistor Q 29 . Again, this voltage can be chosen at a value of about 8 volts. When V GEN  drops below this value, the output OUT 2  of MEM 2  switches to the logic value 0 equal to 0 Volt. 
     According to an embodiment, in the power supply unit P the electrolytic capacitor C 5  may have a predefined capacitance such that it provides power to the entire electronic circuitry inside the rectifier RT through the voltage stabilizer U 7  as well as supporting any charging current peaks in the event of disconnection of the battery B from the rectifier RT. Conveniently, the capacitor C 5  has a capacitance value ranging from 1000 to 2000 μF, preferably about 1500 μF at a voltage of 25 volts. 
     Conveniently, when the generator G is set in rotation by the endothermic engine to which it is mechanically connected, the windings generate a current that, through the six diodes D 7 , D 8 , D 9 , D 10 , D 11 , D 12  charge the capacitor C 5  with a voltage V GEN . As soon as V GEN , through the resistor R 33 , reaches about 0.6 volts, it polarizes the base of Q 25  causing it to saturate, as a result the transistor Q 20  will be interrupted and the transistor Q 21  will be in conduction thus maintaining the voltage between the gate and source of Power MOS Q 22 , Q 23  and Q 24  at zero, therefore interrupted. 
     In this situation, the rectifier RT is separated from the battery by the Power MOS Q 22 , Q 23  and Q 24  until the transistor Q 25  is allowed to switch from saturation to interdiction. This condition is only verified if the output OUT 2  of MEM 2  is at the logic value 1 or V GEN  value. 
     The instant when OUT 2  switches to the logic value 1, the transistor Q 26  switches to saturation and Q 25  interdicts thus allowing Q 20  to drive Power MOS Q 22 , Q 23 , Q 24  in conduction. 
     In case of wrong connection of battery polarity to the rectifier RT, the current crosses the diode of the optoisolator J 1 , through R 29  and D 15  switching the internal transistor of the optoisolator J 1  in conduction. Consequently, the transistors Q 16  and Q 18  will switch to conduction by causing the output OUT 1  of MEM 1  to the logic value 1 that, through R 27  and R 42 , will allow Q 27  and Q 25  to switch to conduction by interdicting the three Power MOS Q 22 , Q 23  and Q 24 . 
     The condition of logic state 1 of the memory MEM 1  will remain until the power supply to the memory itself is cut off, i.e. until the rotor  22  of the generator G is stopped and the battery B is connected with the correct polarity. It follows that this configuration allows the rectifier RT not to be damaged by the incorrect connection of the polarity of battery B as it is disconnected from it. 
     Since MEM 2  is a comparator with hysteresis, the output will switch to the logic value 1 only when V GEN  exceeds a typical value of 12 volts and remain in that state until V GEN  drops below a typical value of 8 volts. 
     In actual facts, this condition allows the generator to begin charging the battery only when the voltage of the generator V GEN , on the capacitor C 5 , has exceeded 12 Volts and is maintained until it drops below 8 Volts; during operation, if there is a short circuit between the positive terminal and the negative terminal, the regulator remains connected to the output until the voltage V GEN  drops below 8 Volts which causes the Power MOS Q 22 , Q 23 , and Q 24  to open. 
     The voltage V GEN  begins to rise again to 12 volts, switching the Power MOS Q 22 , Q 23 , and Q 24  back to conduction, thus allowing the rectifier RT to remain regularly powered without showing overheating problems due to the lack of power. Improper driving of the Power MOS would result in a destructive temperature rise for the devices themselves. 
     Finally, it should be specified that the operating mode described above allows, during the starting phase when the battery voltage may drop to 6 Volts, not to overload the starter motor of the endothermic engine, since the generator G does not supply current to the battery B even when the latter has a lower voltage than 6 Volts. 
     According to a further embodiment, the three-phase windings of the generator G can be connected to the rectifier RT in phase opposition. This type of connection makes it possible to reduce the voltage ripple on the battery B due to the pulsating current in case of intermediate charges. As illustrated in the examples of  FIGS.  5  and  6   , the situation of a charge is represented that absorbs a battery current equal to a quarter of the maximum current that can be delivered by the generator G. With the same average current I BATT S delivered to the battery B in the two cases, the rms value of the current I BATT S is lower in  FIG.  6   . This configuration implies less dissipation along the downstream wiring harnesses  23 ,  24  between the rectifier RT and the battery B and also less voltage ripple on the battery B itself. 
     It has in practice been ascertained that the described invention achieves the intended objects. 
     In particular, the use of an individual rectifier allows keeping the currents in the two output branches of the generator balanced within a compact solution that allows, at the same time, stable adjustments even in cases of battery disconnection or short circuits without affecting the other charges of the vehicle. Obviously, the embodiments and versions described and illustrated hereinabove are to be considered purely for illustrative purposes, and a skilled person in the art may, in order to meet contingent and specific needs, make numerous modifications and variations to the rectifier according to the above-described invention, including for example the combination of said embodiments and versions, all of which are however contained within the scope of protection of the invention as defined by the following claims.