US-20260124923-A1 - SYSTEM AND METHOD FOR MOTOR BASED POWER TRANSFER

Abstract

A power transfer system includes a traction battery pack, a power inverter module configured electrical communication with the traction battery pack, and a rotary electric machine. The rotary electric machine is in electrical communication with the alternating current bus and includes a first set of windings in electrical communication with the alternating current bus and a second set of winding in electrical communication with an output alternating current bus. A power outlet in electrical communication with the second set of windings through the output alternating current bus. A controller in electrical communication with the power inverter module. The controller is configured to selectively direct the power inverter module to direct the alternating current through the alternating current bus to the rotary electric machine to generate a desired output power at the power outlet.

Inventors

• Peng Peng
• Lei Hao
• Thomas W. Nehl
• Suresh Gopalakrishnan
• Renato Amorim Torres

Assignees

• GM Global Technology Operations LLC

Dates

Publication Date

20260507

Application Date

20241104

Claims (20)

1. 1 . A power transfer system, comprising: a traction battery pack; a power inverter module configured to receive a high-voltage direct current from the traction battery pack and convert the high-voltage direct current into an alternating current that is configured to be received by an alternating current bus; a rotary electric machine in electrical communication with the alternating current bus, wherein the rotary electric machine is a segmented winding machine and includes a first set of windings in electrical communication with the alternating current bus, a second set of winding in electrical communication with an output alternating current bus, and the second set of windings is electrically isolated from the power inverter module; a power outlet in electrical communication with the second set of windings through the output alternating current bus; and a controller in electrical communication with the power inverter module, wherein the controller is configured to: selectively direct the power inverter module to direct the alternating current through the alternating current bus to the rotary electric machine to generate a desired output power at the power outlet.
2. 2 . The power transfer system of claim 1 , wherein the first set of windings are low-turn windings and the second set of windings are high-turn windings, the rotary electric machine includes a three-phase rotary electric machine, and the first set of windings are electrically isolated from the output alternating current bus.
3. 3 . The power transfer system of claim 1 , wherein the first set of windings are located radially inward from the second set of windings in a stator of the rotary electric machine relative to an axis of rotation of a rotor in the rotary electric machine and the rotary electric machine includes a stator having plurality of teeth and a portion of the first set of windings and a portion of the second set of windings surround a corresponding one of the plurality of teeth on the stator.
4. 4 . The power transfer system of claim 3 , wherein the second set of windings includes three sets of windings each having a corresponding output in electrical communication with the output alternating current bus.
5. 5 . The power transfer system of claim 4 , wherein a first winding of the three sets of windings in the second set of windings is selectively connectable to the power outlet through a second windings of the second set of windings by a switch and the controller is configured to selectively actuate the switch to provide a three-phase alternating current in a first switch position or a single-phase alternating current in a second switch position through the output alternating current bus to the power outlet.
6. 6 . The power transfer system of claim 4 , wherein the desired output power includes a three-phase alternating current, the output alternating current bus is a three-phase current bus, and the controller is configured to disengage a drivetrain from the rotary electric machine while the alternating current is directed through the alternating current bus to the rotary electric machine.
7. 7 . The power transfer system of claim 6 , wherein the rotor is an eight pole rotor and the controller is configured to direct the rotary electric machine to rotate the rotor at 900 RPM.
8. 8 . The power transfer system of claim 6 , wherein the rotor is a six pole rotor and the controller is configured to direct the rotary electric machine to rotate the rotor at 1200 RPM.
9. 9 . The power transfer system of claim 1 , wherein the desired output power includes a single phase alternating current and the second set of windings includes only two sets of windings with each of the two sets of windings selectively connected to the power outlet by a corresponding switch for providing single-phase alternating current to the power outlet
10. 10 . The power transfer system of claim 1 , wherein the second set of windings include between 8 and 10 times as many turns as the first set of windings.
11. 11 . A method of performing power transfer, the method comprising: directing a power inverter module to convert direct current from a traction battery pack from a direct current bus into a three-phase alternating current received by an alternating current bus; directing the three-phase alternating current into a rotary electric machine, wherein the rotary electric machine is a segmented winding machine and includes a first set of windings in electrical communication with the alternating current bus, a second set of winding in electrical communication with an output alternating current bus, and the first set of windings are electrically isolated from the output alternating current bus; and directing an alternating current generated in the second set of windings through the output alternating current bus to a power outlet.
12. 12 . The method of claim 11 , wherein the first set of windings are low-turn windings and the second set of windings are high-turn windings, the first set of windings are located radially inward from the second set of windings, and the rotary electric machine includes a stator having plurality of teeth and a portion of the first set of windings with a portion of the second set of windings surrounding a corresponding one of the plurality of teeth on the stator.
13. 13 . The method of claim 12 , wherein the second set of windings includes three sets of windings configured to provide three-phase alternating current from each of the second set of windings to the output alternating current bus and the second set of windings are electrically isolated from the power inverter module.
14. 14 . The method of claim 13 , including directing a rotational speed of a rotor in the rotary electric machine to synchronize a frequency, amplitude, and phase of the alternating current generated in the second set of windings with a load in electrical communication with the power outlet.
15. 15 . The method of claim 14 , including disengaging the rotary electric machine from a drivetrain of a vehicle when directing the rotational speed of the rotor in the rotary electric machine to synchronize the frequency, amplitude, and phase of the alternating current generated in the second set of windings with the load in electrical communication with the power outlet.
16. 16 . The method of claim 12 , wherein the second set of windings include three sets of windings each having a corresponding output and first winding of the three sets of windings in the second set of windings is selectively connectable to the power outlet through a second windings of the second set of windings by a switch configured to selectively provide a three-phase alternating current in a first switch position or a single-phase alternating current in a second switch position through the output alternating current bus to the power outlet.
17. 17 . A vehicle comprising: a vehicle body supported by a plurality of wheels; a traction battery pack fixed relative to the vehicle body; a power inverter module configured to receive a high-voltage direct current from the traction battery pack and convert the high-voltage direct current into an alternating current that is configured to be received by an alternating current bus; a rotary electric machine in electrical communication with the alternating current bus and configured to drive the plurality of wheels through a drivetrain, wherein the rotary electric machine is a segmented winding machine and includes a first set of windings in electrical communication with the alternating current bus and a second set of winding in electrical communication with an output alternating current bus, and the second set of windings is electrically isolated from the power inverter module; a power outlet in electrical communication with the second set of windings through the output alternating current bus; and a controller in electrical communication with the power inverter module, wherein the controller is configured to: selectively direct the power inverter module to direct the alternating current through the alternating current bus to the rotary electric machine to generate a desired output power at the power outlet.
18. 18 . The vehicle of claim 17 , wherein the first set of windings are low-turn windings and the second set of windings are high-turn windings, the first set of windings are located radially inward from the second set of windings in a stator of the rotary electric machine relative to an axis of rotation of a rotor in the rotary electric machine and the rotary electric machine includes a stator having plurality of teeth and a portion of the first set of windings and a portion of the second set of windings surround a corresponding one of the plurality of teeth on the stator.
19. 19 . The vehicle of claim 18 , wherein the second set of windings includes three sets of windings each having a corresponding output in electrical communication with the output alternating current bus, the rotary electric machine includes a three-phase rotary electric machine, and the first set of windings are electrically isolated from the output alternating current bus.
20. 20 . The vehicle of claim 19 , wherein a first winding of the three sets of windings in the second set of windings is selectively connectable to the power outlet through a second windings of the second set of windings by a switch and the controller is configured to selectively actuate the switch to provide a three-phase alternating current in a first switch position or a single-phase alternating current in a second switch position through the output alternating current bus to the power outlet.

Description

BACKGROUND Fully electric or hybrid electric vehicles are capable of achieving greater range through advancements in battery technology and capacity. Certain batteries, such as traction batteries, provide power in the form of direct current (“DC”). The DC power from the traction battery can be converted to alternative current (“AC”) by a power module to drive a traction motor or operate another portion of the vehicle. As the traction batteries can store large amounts of power, utilizing a portion of that power for purposes other than propulsion can be beneficial. For example, a user of the vehicle may want to power small electronic devices when in remote areas, to provide power to a home during a power outage, or to provide power directly to a grid. In one example, to convert the DC power from the traction battery to power that can be utilized by other sources, a second power module is linked to the traction battery separate from the power module used to drive the traction motor. SUMMARY Disclosed herein is a power transfer system. The system includes a traction battery pack, a power inverter module configured to receive a high-voltage direct current from the traction battery pack and convert the high-voltage direct current into an alternating current that is configured to be received by an alternating current bus, and a rotary electric machine. The rotary electric machine is in electrical communication with the alternating current bus and is a segmented winding machine that includes a first set of windings in electrical communication with the alternating current bus and a second set of winding in electrical communication with an output alternating current bus. A power outlet in electrical communication with the second set of windings through the output alternating current bus. A controller in electrical communication with the power inverter module. The controller is configured to selectively direct the power inverter module to direct the alternating current through the alternating current bus to the rotary electric machine to generate a desired output power at the power outlet. In one aspect of the disclosure the first set of windings are low-turn windings and the second set of windings are high-turn windings. In one aspect of the disclosure the first set of windings are located radially inward from the second set of windings in a stator of the rotary electric machine relative to an axis of rotation of a rotor in the rotary electric machine. In one aspect of the disclosure the second set of windings includes three sets of windings each having a corresponding output in electrical communication with the output alternating current bus. In one aspect of the disclosure a single set of winding of the three sets of windings is selectively connectable to the power outlet by a switch for providing one of a three-phase alternating current or a single-phase alternating current to the power outlet. In one aspect of the disclosure the desired output power includes a three-phase alternating current and the controller is configured to disengage a drivetrain from the rotary electric machine. In one aspect of the disclosure the rotor is an eight pole rotor and the controller is configured to direct the rotary electric machine to rotate the rotor at 900 RPM. In one aspect of the disclosure the rotor is a six pole rotor and the controller is configured to direct the rotary electric machine to rotate the rotor at 1200 RPM. In one aspect of the disclosure the desired output power includes a single phase alternating current and the second set of windings includes two sets of windings. In one aspect of the disclosure the second set of windings include between 8 and 10 times as many turns as the first set of windings. Disclosed herein is a method of performing power transfer. The method includes directing a power inverter module to convert direct current from a traction battery pack from a direct current bus into a three-phase alternating current received by an alternating current bus. Th method also includes directing the three-phase alternating current into a rotary electric machine. The rotary electric machine is a segmented winding machine and includes a first set of windings in electrical communication with the alternating current bus and a second set of winding in electrical communication with an output alternating current bus. The method also includes directing an alternating current generated in the second set of windings through the output alternating current bus to a power outlet. In one aspect of the disclosure the first set of windings are low-turn windings and the second set of windings are high-turn windings and the first set of windings are located radially inward from the second set of windings. In one aspect of the disclosure the second set of windings include three sets of windings configured to provide three-phase alternating current from the second set of windings to the output alternating current bus. In one