US-20260124939-A1 - BATTERY CHARGING SYSTEM INCLUDING ISOLATED POWER SPLITTER OPERATING IN SIMULTANEOUS CHARGING AND DISCHARGING MODE

US20260124939A1US 20260124939 A1US20260124939 A1US 20260124939A1US-20260124939-A1

Abstract

A battery charging system for a vehicle includes a multi-port transformer including first, second, and third windings. A first converter is connected to the first windings and includes a first plurality of switches. A second converter is connected to the second windings and a battery and includes a second plurality of switches. A third converter is connected to the third windings and to an alternating current (AC) power outlet and includes a third plurality of switches. A first plurality of configuration switches is configured to selectively connect the first converter to a charge port. A controller is configured to control the first, second, and third plurality of switches of the first, second, and third converters, the first plurality of configuration switches, and the second plurality of configuration switches to select one of a plurality of charging modes of the battery charging system.

Inventors

Minh-Khai Nguyen
Firas Shabo
Brian A. Welchko

Assignees

GM Global Technology Operations LLC

Dates

Publication Date: 20260507
Application Date: 20241101

Claims (20)

1 . A battery charging system for a vehicle comprising: a multi-port transformer including first windings, second windings, and third windings wound around a common core; a first converter connected to the first windings and including a first plurality of switches; a second converter connected to the second windings and a battery and including a second plurality of switches; a third converter connected to the third windings and to an alternating current (AC) power outlet and including a third plurality of switches; a first plurality of configuration switches configured to selectively connect the first converter to a charge port; and a controller configured to control the first plurality of switches of the first converter, the second plurality of switches of the second converter, the third plurality of switches of the third converter, the first plurality of configuration switches, and the second plurality of configuration switches to select one of a plurality of charging modes of the battery charging system.
2 . The battery charging system of claim 1 , further comprising: a ground fault circuit interrupter (GFCI) connected between the third converter and the AC power outlet; a second plurality of configuration switches configured to selectively connect the first converter to the second converter; and a third plurality of configuration switches configured to selectively connect the third converter to the AC power outlet.
3 . The battery charging system of claim 2 , wherein the plurality of charging modes include: a charging mode for charging the battery, a charging/discharging mode for charging the battery from an AC grid via the charge port while supplying power to the AC power outlet, and a discharging/discharging mode for discharging the battery to a load via the charge port while supplying power to the AC power outlet.
4 . The battery charging system of claim 3 , wherein, during the charging mode, the controller is configured to close the first plurality of configuration switches and the second plurality of configuration switches and open the third plurality of configuration switches.
5 . The battery charging system of claim 4 , wherein, during the charging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the charge port, the first converter and the second converter to the third converter and the battery.
6 . The battery charging system of claim 3 , wherein, during the charging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches.
7 . The battery charging system of claim 6 , wherein, during the charging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the first converter to the second converter and the battery and through the first converter and the third converter to the AC power outlet.
8 . The battery charging system of claim 3 , wherein, during the discharging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches.
9 . The battery charging system of claim 8 , wherein, during the discharging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the battery through the second converter, the first converter, and the charge port and through the second converter and the third converter to the AC power outlet.
10 . The battery charging system of claim 3 , wherein the AC grid supplies three-phase AC current.
11 . The battery charging system of claim 3 , wherein the AC grid supplies single-phase AC current.
12 . A battery charging system for a vehicle comprising: a multi-port transformer including first windings, second windings, and third windings wound around a common core; a first converter connected to the first windings and including a first plurality of switches; a first electromagnetic interference (EMI) filter connected to the first converter; a second converter connected to the second windings and including a second plurality of switches; a second EMI filter connected to the second converter and to a battery; a third converter connected to the third windings and including a third plurality of switches; a third EMI filter connected to the third converter and an alternating current (AC) power outlet; a ground fault circuit interrupter (GFCI) connected between the third converter and the AC power outlet; a first plurality of configuration switches configured to selectively connect the first EMI filter to a charge port; a second plurality of configuration switches configured to selectively connect the first converter to the second converter; a third plurality of configuration switches configured to selectively connect the third converter to the AC power outlet; and a controller configured to control the first plurality of switches of the first converter, the second plurality of switches of the second converter, the third plurality of switches of the third converter, the first plurality of configuration switches, and the second plurality of configuration switches to select one of: a charging mode for charging the battery, a charging/discharging mode for charging the battery from an AC grid via the charge port while supplying power to the AC power outlet, and a discharging/discharging mode for discharging the battery to via the charge port to a load while supplying power to the AC power outlet.
13 . The battery charging system of claim 12 , wherein, during the charging mode, the controller is configured to close the first plurality of configuration switches and the second plurality of configuration switches and open the third plurality of configuration switches.
14 . The battery charging system of claim 13 , wherein, during the charging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the first converter and the second converter to the third converter and the battery.
15 . The battery charging system of claim 12 , wherein, during the charging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches.
16 . The battery charging system of claim 15 , wherein, during the charging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the first converter to the second converter and the battery and through the first converter and the third converter to the AC power outlet.
17 . The battery charging system of claim 12 , wherein, during the discharging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches.
18 . The battery charging system of claim 17 , wherein, during the discharging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the battery through the second converter and the first converter to the charge port and through the second converter and the third converter to the AC power outlet.
19 . The battery charging system of claim 12 , wherein the AC grid supplies single-phase AC current.
20 . The battery charging system of claim 12 , wherein the AC grid supplies three-phase AC current.

Description

INTRODUCTION The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure. The present disclosure relates to a battery charging system including an isolated power splitter. Electric vehicles (EVs) such as battery electric vehicles (BEVs), hybrid vehicles, and/or fuel cell vehicles include one or more electric machines and a battery including one or more battery cells, modules, and/or packs. A battery charging system is used to control charging from an alternating current (AC) grid or supplying power from the battery to the AC grid or another load. SUMMARY A battery charging system for a vehicle includes a multi-port transformer including first windings, second windings, and third windings wound around a common core. A first converter is connected to the first windings and includes a first plurality of switches. A second converter is connected to the second windings and a battery and includes a second plurality of switches. A third converter is connected to the third windings and to an alternating current (AC) power outlet and includes a third plurality of switches. A first plurality of configuration switches is configured to selectively connect the first converter to a charge port. A controller is configured to control the first plurality of switches of the first converter, the second plurality of switches of the second converter, the third plurality of switches of the third converter, the first plurality of configuration switches, and the second plurality of configuration switches to select one of a plurality of charging modes of the battery charging system. In other features, a ground fault circuit interrupter (GFCI) connected between the third converter and the AC power outlet. A second plurality of configuration switches is configured to selectively connect the first converter to the second converter. A third plurality of configuration switches is configured to selectively connect the third converter to the AC power outlet. In other features, the plurality of charging modes include a charging mode for charging the battery, a charging/discharging mode for charging the battery from an AC grid via the charge port while supplying power to the AC power outlet, and a discharging/discharging mode for discharging the battery to a load via the charge port while supplying power to the AC power outlet. In other features, during the charging mode, the controller is configured to close the first plurality of configuration switches and the second plurality of configuration switches and open the third plurality of configuration switches. During the charging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the charge port, the first converter and the second converter to the third converter and the battery. In other features, during the charging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches. In other features, during the charging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the AC grid through the first converter to the second converter and the battery and through the first converter and the third converter to the AC power outlet. In other features, during the discharging/discharging mode, the controller is configured to close the first plurality of configuration switches and the third plurality of configuration switches and open the second plurality of configuration switches. In other features, during the discharging/discharging mode, the controller is configured to control the first plurality of switches, the second plurality of switches, and the third plurality of switches to supply current from the battery through the second converter, the first converter, and the charge port and through the second converter and the third converter to the AC power outlet. In other features, the AC grid supplies three-phase AC current. The AC grid supplies single-phase AC current. A battery charging system for a vehicle includes a multi-port transformer including first windings, second windings, and third windings wound around a common core. A first converter is connected to the first windings and includes a first plurality of switches. A first electromagnetic interference (EMI) filter is connected to the first converter. A second converter is connected to the second win