US 20160214493A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2016/0214493 A1 Herke et al. (43) Pub. Date: Jul. 28, 2016
(54) HIGH-VOLTAGE CHARGE BOOSTER AND Publication Classification METHOD FOR CHARGING A DIRECT CURRENT TRACTION BATTERY AT A (51) Int. Cl. DIRECT CURRENT CHARGING PLLAR AND B60L. II/IS (2006.01) CORRESPONDINGELECTRIC VEHICLE (52) U.S. Cl. CPC ...... B60L 1 1/1811 (2013.01); B60L 1 1/1861 (71) Applicant: Dr. Ing. h.c. F. Porsche (2013.01); B60L 11/1818 (2013.01); B60L Aktiengesellschaft, Stuttgart (DE) I 1/1848 (2013.01) (72) Inventors: Dirk Herke, Kirchheim unter Teck (57) ABSTRACT (DE); Daniel Spesser, Illingen (DE) A high-voltage charge booster is provided for charging a (21) Appl. No.: 15/006,175 direct current traction battery at a direct current charging pillar. The high-voltage charge booster has a converter (14) (22) Filed: Jan. 26, 2016 for transforming the first voltage level into the second Voltage level if the first voltage level differs from the second voltage (30) Foreign Application Priority Data level. A bypass (16) bypasses the converter (14) or connects through a power stage if the first Voltage level corresponds to Jan. 28, 2015 (DE) ...... 10 2015 101 187.5 the second Voltage level.
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200A (800V) 28A (800V) I, I 55A (400W. l r 22kW
AC3-32A
24 Patent Application Publication Jul. 28, 2016 Sheet 1 of 2 US 2016/0214493 A1
14 L1 D1 l L D c Vin NMOSQ1 | Vout
Fig. 1
290A (800V) 23A (800V)
Fig. 2 24 Patent Application Publication Jul. 28, 2016 Sheet 2 of 2 US 2016/0214493 A1 31-O 32-CD 43 33-O Vin 34
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4. 2 US 2016/0214493 A1 Jul. 28, 2016
HGH-VOLTAGE CHARGE BOOSTER AND 0011. A non-electrically isolated, bidirectional converter METHOD FOR CHARGING A DIRECT with selectable direction of power flow and a voltage range of CURRENT TRACTION BATTERY AT A the feeding direct current infrastructure between 200 and 700 DIRECT CURRENT CHARGING PLLAR AND V is considered. The Voltage range can be bypassed when an CORRESPONDINGELECTRIC VEHICLE 800V infrastructure is present or can be switched to a passive state by connecting through the power stage in favor of a CROSS REFERENCE TO RELATED direct charging process. The output Voltage at the high-volt APPLICATION age battery is above the input voltage between 450 and 950 V 0001. This application claims priority under 35 USC 119 given a ripple of less than 1% and is controlled by internal to German Patent Appl. No. 10 2015 101 187.5 filed on Jan. Voltage regulation and current regulation by Software. 28, 2015, the entire disclosure of which is incorporated herein 0012. The converter can be configured so that, given a by reference. power of up to 200 kW and above, the booster charges the traction battery with an output current between 175A and 200 BACKGROUND A if the charging pillar feeds the booster with an input current between 330 A and 350 A, the first voltage level is between 0002 1. Field of the Invention. The invention relates to a 200 V and 600 V, and the second voltage level is 700 to 900 V. high-voltage charge booster for charging a direct current trac wherein future embodiments may support significantly tion battery at a direct current charging pillar. The invention higher Voltage levels. In this way, a maximum utilization of also relates to a corresponding electric Vehicle, method, com the 400 V charging infrastructure is achieved by constant puter program and storage medium. charging with up to 450 V, and with the charging time being 0003 2. Description of the Related Art. The prior art com correspondingly reduced with respect to conventional AC prises electric vehicles having a direct current traction battery charging. In this context, the independence of the increase in with, for example, a direct current voltage level of 800V. The the Voltage is maintained by the high-voltage battery via its electric vehicle is connected inductively or by a cable to a state of charge, which corresponds to a power advantage of 25 stationary alternating current power system via a charging kW given a charging current of 350 A. pillar to charge the traction battery. Charging then can be 0013 The booster may have a volumetric capacity of less carried out directly with direct current when an AC/DC con than 6 I. The required installation space therefore corresponds Verter is integrated into the charging pillar. Alternating cur to that of an 11 kW on-board charging device, which opens up rent can be used for charging, but requires an AC/DC con many possible supply options with respect to correspond verter integrated into the electric vehicle. ingly equipped vehicles. A vehicle can be retrofitted to 22 kW 0004 US 2008/0215200 A1 discloses a control system alternating current charging in a neutral way in terms of and hybrid vehicles with re-configurable multifunction installation space given an 800 V infrastructure which is power inverter. This document also describes an actuation provided extensively. method for charging with alternating current. 0014. An exemplary embodiment of the invention is pre 0005 US 2010/0231169 A1 explains general energy con sented in the drawings and will be described in more detail version on the basis of a charging Voltage of for example, 450 below. V with different high voltages in an electric vehicle. 0006 US 2011/0148353 A1 relates to a device and to a BRIEF DESCRIPTION OF THE DRAWINGS method for rapidly charging by means of divided power elec tronics and describes primarily the design of direct current 0015 FIG. 1 shows the circuit diagram of a device for charging pillars whose direct current bus is fed by the energy charging a traction battery at a direct current charging pillar conversion of an alternating current. given a voltage level of 400 V. 0007 US 2012/0049794 A1 discloses an AC charging (0016 FIG. 2 shows the system overview of a 400 V device that Supplies two high-voltage batteries. booster according to one embodiment of the invention. 0017 FIG. 3 shows the program flow chart of a computer SUMMARY program according to a further embodiment of the invention. 0008. The invention provides a high-voltage charge DETAILED DESCRIPTION booster for charging a direct current traction battery at a direct current charging pillar, a corresponding electric vehicle, a 0018 FIG. 1 illustrates the requirements of an electric method, computer program and storage medium. vehicle with respect to the charging of a traction battery 12 at 0009. An advantage of the invention is its independence a direct current charging pillar given a voltage level of 400 V. from the design of an 800V infrastructure and relevant coun The relevant configuration criteria comprise a power of 150 try-specific and political decisions. This independence is kW for transforming the first voltage level Vin of 450 V of a achieved by using an existing 400 V infrastructure. In this direct current charging pillar into a second Voltage level Vout way, the invention is capable of deciding in a universally between 600 V and 900 V, in particular of 800V. In this case, intelligent fashion that charging compatibility will be ensured on the 450 V side there is a resulting input current of 333 A. in the next few years on a worldwide basis. which suggests configuration for 350 A, while on the 800 V 0010. The invention is based on the realization that it is side an output current of 175 A occurs. possible to decide automatically between a direct voltage of 0019. The converter 14 shown in FIG. 1 essentially satis 400 V and one of 800 V and that if 400 V is present, it is fies the specified requirements. The question as to the imple possible to Switch over automatically by a Switching matrix mentation of a bypass for 800 V remains open. and to activate a converter. Alternatively, it is possible to 0020. The inventive high-voltage charge booster 10 of charge even more quickly in parallel on a new 800 V infra FIG. 2 comprises such a bypass 16 that electrically bypasses Structure. the converter 14 if the first voltage level Vin of the charging US 2016/0214493 A1 Jul. 28, 2016 pillar corresponds to the second voltage level Vout of the to monitoring 45 by the fourth software module. During the traction battery 12. On the other hand, if the first voltage level conversion 46 of energy to the second voltage level Vout of Vin differs from the second voltage level Vout, the converter 800 V, performed by the 800 V booster 10, in a ninth method 14 is not bypassed by the bypass 16, but instead transforms step 39 the seventh software module checks the plausibility of the first voltage level Vin into the second voltage level Vout. the charging currents which are signaled by the sixth Software This would have to be assumed, for example, in the switch module of the infrastructure, with respect to the actual values position of the bypass 16 according to the FIG. 2, in which of the 800 V booster 10. In a tenth method step 40, the eighth switch position the charging pillar feeds the booster 10 with Software module starts and stores all the environmental data. an input current between 330 A and 350 A, and the first 0026. The second software module which is, as it were, voltage level Vin is between 400 V and 450 V, and the second entrusted with a “watchdog function monitors, for its part, voltage level Vout is 800V. In this scenario, given a power of the entire charging operation in parallel in an eleventh method 150 kW the booster 10 charges the traction battery 12 with an step 41 and manages the first Software module, third software output current of up to 200 A, with the result that the traction module, fourth software module, fifth software module, sixth battery 12 feeds the electric motor 18 of the electric vehicle software module, seventh software module and eighth soft 10, 12, 18, 19, 20, 22, 24 (not illustrated in its entirety) via its ware module, until finally, in a twelfth method step 42, the rear power electronics 19. ninth Software module ends the charging process by means of 0021. In addition to the components already mentioned, radio remote control, a keypad or touch pad or the charging the electric vehicle 10, 12, 18, 19, 20, 22, 24 comprises two infrastructure itself. on-board charging devices 20, 22, which, given a respective What is claimed is: power of 11 kW. charge the traction battery 12 with an output 1. A high-voltage charge booster for charging a traction current of 28 A if a correspondingly configured alternating battery at a direct current charging pillar, the charging pillar current charging Socket Supplies the on-board charging having a first Voltage level (V) and the traction battery device 20, 22 via its charging Socket 24 with a three-phase having a second Voltage level (V), the high-voltage charge input current of up to 32 A. booster comprising: 0022. The method for charging the explained electric a converterfor transforming the first Voltage level (V) into vehicle 10, 12, 18, 19, 20, 22, 24 at a direct current charging the second voltage level (V) if the first voltage level pillar with a first direct current voltage level of 400 V will now (V) differs from the second Voltage level (V), and be explained with reference to the sequencing control which a bypass for bypassing the converter or connecting through is outlined by FIG.3 and which may be located either in the a power stage if the first voltage level (V) corresponds on-board charging device 20, 22 or in the booster 10. The to the second Voltage level (V). corresponding Software function comprises for this purpose a 2. The high-voltage charge booster of claim 1, wherein the first software module for boost control, a second software converter is configured bidirectionally so that, given a power module for detection and plausibility-checking of the boost of up to 150 kW the booster, the converter charges the traction operation, a third software module for evaluating the actual battery with an output current of up to more than 200A if the state of the relevant components, a fourth software module for charging pillar feeds the booster with an input current boost derating, a fifth software module for activating the between 330 A and 350 A, the first voltage level (V) is boost contactor, a sixth software module for PLC boost con between 200 V and 450 V, and the second voltage level (V) trol with the charging infrastructure, a seventh software mod is 800 V. ule for plausibility-checking of the charging currents, an 3. The high-voltage charge booster of claim 1, wherein the eighth software module for historical values and a ninth soft booster has a volumetric capacity of approximately 6 I. ware module for ending the boosting. 4. An electric Vehicle, comprising: 0023. In a first method step 31, the electric vehicle 10, 12, 18, 19, 20, 22, 24 is connected here to a 400 V direct current an electric motor for driving the electric vehicle, infrastructure. In a second method step 32, the third software a traction battery for feeding the electric motor, module evaluates whether the 800 V booster 10 is operation at least one on-board charging device for charging the ally capable. In the case of proven operational capability 43. traction battery at an alternating current charging Socket, the sixth software module then evaluates in a third method the high-voltage charge booster of claim 1 for charging the step 33 whether a 400 V or 800V charging pillar is connected traction battery at a direct current charging pillar, to the electric vehicle 10, 12, 18, 19, 20, 22, 24. cabling of the bypass and 0024. If this evaluation leads to the detection of a first an on-board computer connected by cable to the high voltage level Vin of 400 V, the PLC starts, in a fourth method Voltage charge booster. step 34, to exchange all the charging-relevant information. In 5. The electric vehicle of claim 4, wherein: a fifth method step 35, the first software module calculates all the electric Vehicle comprises two on-board charging the direct-current-charging-relevant information and trans devices and mits it to the infrastructure. For example a setpoint current or the on-board charging devices are configured so that, given a setpoint voltage are considered. The fourth software module a respective power of 11 kW, the on-board charging then checks, in a sixth method step 36, whether the calculated devices charge the traction battery with an output current power can be transmitted by the 800 V booster 10. If the of 28A if the charging Socket feeds the on-board charg satisfactory checking reveals that this power can be transmit ing device with a three-phase input current of up to 32 A, ted without restriction 44, the fourth software module starts and the second voltage level (V)data is 700 to 900 V or the charging process in a seventh method step 37. O. 0025. In an eighth method step 38, the fifth software mod 6. A method for charging the electric vehicle of claim 4 at ule controls the Switching of the contactor for the connection a direct current charging pillar with a first voltage level (V) of power to the 800 V booster 10 and is subject in the process of 400 V. comprising: US 2016/0214493 A1 Jul. 28, 2016
connecting the electric Vehicle to the charging pillar, the availability checking of the power and recording of the evaluating the operational capability of the booster, charging process are carried out by means of a fourth detecting the first voltage level (V) for a given operational Software module for throttling the charging process, capability, the connecting of the power is carried out by a fifth soft initiating an exchange of information with the charging ware module for Switching over a contactor, pillar for a detected first voltage level (V), the detecting of the first voltage level (V) is carried out by transmitting charging-relevant information to the charging a sixth software module for communicating with the pillar, charging pillar, availability testing a required power of the booster, recording a charging process, the plausibility-checking of the charging currents is carried connecting the power to the booster, out by a seventh software module for checking the plau plausibility-checking a charging current flowing from the sibility of the charging currents, charging pillar, the storing of the environmental data is carried out by an storing environmental data, eighth software module for storing historical data, and monitoring the charging process, and the ending of the charging process is carried out by a ninth ending of the charging process. Software module for ending the charging process. 7. The method of claim 6, wherein: 8. The method as of claim 7, wherein a software function the transmitting of the charging-relevant information is that is located in the on-board charging device or in the carried out by a first software module for controlling the booster comprises the Software modules. charging process, 9. A computer program configured to carry out all the steps the monitoring of the charging process is carried out by a of the method of claim 6. second Software module for detecting and checking the plausibility of the charging process, 10. A machine-readable storage medium having a com the evaluation of the operational capability is carried out by puter program Stored thereon, as claimed in claim 9. a third Software module for evaluating an actual state, k k k k k