Gm Global Technolgoy Operations, Inc.

Andrew J Namou

Mohammad N Anwar

Todd F Mackintosh

Ahmad Albanna

Syed M Kadry

Herman K Phlegm

Mahmoud H Abd Elhamid

Russell K Steele

Brandon R Jones

Milind S Gandhi

David J Mifsud

Andrew C Brenz

Chandra S Namuduri

Chih-Cheng Hsu

James E Tarchinski

Christopher A Schlaupitz

Douglas S Cesiel

John Reed

Stephen M Cichy

Ryan M Ashby

Brian James Koch

Damon R Frisch

Xidong Tang

Aniket P Kothari

Robert Charles Baraszu

Kenneth J Shoemaker

Yue Fan

Jian Lin

Edgar P Calderon

Andres V Mituta

Joseph M Lograsso

Marc Reischmann

Roland Matthe

Marjorie A Bassham

Robert D Drexler

David S Maxwell

Paul Stephen Zombory

Rezina S Nabi

Gregory G Cesiel

Helen X Qin

Cotrina C Connolly

Lisa J Gross

Kevin M Robert

Michael E Barton

Disclosed are control algorithms and system architectures for arbitrating vehicle charging, e.g., for electric vehicles with rechargeable battery packs, wired and wireless charging capabilities, and control logic for governing such charging. A method is disclosed for managing charging of electrical storage units of motor vehicles at vehicle charging stations. The method includes determining if a wireless charging interface of the motor vehicle is available for wireless power transfer, and determining whether or not the vehicle charging station has an electrical connector coupled to a wired charging interface of the motor vehicle. Responsive to the charging station having an electrical connector coupled to the wired charging interface, the method initiates a wired (conductive) charge power mode. Conversely, if the wireless charging interface is available for power transfer and an electrical connector is not coupled to the wired charging interface, the method responsively initiates a wireless (inductive) charge power mode.

Vehicle architectures, electrical systems, and control algorithms for arbitrating vehicle charging

A system and method for discharging a high voltage vehicle battery. The system includes a discharge circuit having a reference voltage source providing a reference voltage and a load for discharging the battery. A negative terminal of the voltage source is electrically coupled to a negative terminal of the battery so that upon initiation of the discharging sequence, the battery is discharged through the load to the reference voltage. The discharge circuit can be electrically configured so that the battery, the voltage source and the load are electrically coupled in series or the battery, the voltage source and the load are electrically coupled in parallel.

Discharge circuit for discharging a battery

A delayed charging system for a vehicle implements an energy transfer efficiency check prior to the scheduled charge time to confirm sufficient grid power quality and wireless power quality. In addition to this, a foreign object check is performed prior to the scheduled charge. These checks are performed immediately after the customer sets up the delayed session as well as at specified intervals after that. If a power quality issue is detected, the customer will be alerted so they can remedy the situation.

Wireless power quality alert for delayed charging with electric vehicles

An onboard charging system for charging from a power source may include an energy storage system. A connector may be configured to couple the onboard charging system with the power source. A charging circuit may be electrically connected between the connector and the energy storage system. A converter may be electrically connected in the charging circuit between the connector and the energy storage system. A rectifier may be electrically connected in the charging circuit between the connector and the converter. Output of an inductive receiver may be electrically connected with the charging circuit between the connector and the converter. The converter may control the delivery of voltage and current to the energy storage system from the power source and from the inductive receiver.

Inductive and conductive onboard charging systems

A conductive charging system for use with an offboard AC or DC power supply and a plug-in vehicle includes a conductive armature, an electromagnetic relay, and a switch. The armature is connected directly to the power supply and deploys into electrical contact with the vehicle in response to the vehicle weight. The switch closes in response to the vehicle weight to connect an auxiliary power device to an inductive coil. The relay moves to a first position connecting the charge coupler to an AC-DC converter or the battery pack when the switch is open, and to a second position bypassing the charge coupler when the switch is closed. A vehicle includes the system, charge coupler, HV battery pack, auxiliary power device, and armature.

Hands-free conductive battery charger for an electric vehicle

A disconnect architecture for use with a system having a battery pack and positive and negative bus rails includes a mid-pack low-power (LP) relay, a fuse, semiconductor switches, and a sequencer circuit. The mid-pack LP relay is positioned between the rails at a mid-stack point of the battery pack, and divides a voltage across the battery pack when commanded open. The fuse is positioned between the mid-pack LP relay and the positive bus rail, and opens in response to a dead short condition of the system. The semiconductor switches are positioned in electrical parallel with the mid-pack LP relay. The sequencer circuit selectively turns on the semiconductor switches and thereby coordinates a flow of electrical current through the semiconductor switches and the mid-pack LP relay in response to a detected partial short condition of the system. A system includes the battery pack, bus rails, and disconnect architecture.

Voltage disconnect architecture

Disclosed are control algorithms and system architectures for managing wireless vehicle charging, including vehicles with rechargeable battery packs, wireless charging capabilities, and control logic for governing such charging. A method is disclosed for managing charging of an electrical storage unit of a motor vehicle at a wireless vehicle charging station. The method includes: receiving a sensor signal indicating detection of an obstruction within a predetermined proximity of the vehicle charging station; determining whether the detected obstruction is living or lifeless; initiating, via a vehicle controller responsive to the detected obstruction being a living object, a first remedial action strategy that commands the vehicle to generate a visual or audible cue to drive away the living object; and, initiating, via the vehicle controller responsive to the detected obstruction being a lifeless object, a second remedial action strategy that commands the motor vehicle to move and thereby avoid contact with the object.

Vehicle architectures, devices and control algorithms for managing wireless vehicle charging

An electrical system includes a contactor having a pair of contacts and a coil configured to electrically close and open the contacts. The electrical system also includes a high voltage ('HV') circuit including a power supply electrically connected to at least one of the contacts of the contactor. The electrical system further includes a low voltage ('LV') circuit electrically connected to the coil and configured to selectively energize the coil of the contactor. A disconnect mechanism is coupled with the LV electrical circuit and operable to electrically open the LV electrical circuit to actuate electrical opening of the contacts of the contactor.

High voltage electrical systems and disconnect mechanisms

An electrical system connectable to an offboard power supply includes a battery pack, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller initiates charging of the battery pack using analog low-voltage signals. A charging preference may prioritize charging via a designated one of the charging systems. Another electrical system includes a battery pack connected to a DC voltage bus, a charge coupler connectable to the offboard power supply to establish a plug-in charging connection, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller commands charging using the analog low-voltage control signals, doing so via the conductive charging system when the charge coupler is plugged into the power supply and via the wireless charger when the charge coupler is not plugged into the power supply and the controller detects proximity of the system to the primary induction coil.

Dual inductive/conductive DC-coupled charging system

A high-voltage battery assembly includes a high-voltage battery electrically connected to a high-voltage bus including a positive rail and a negative rail, wherein the negative rail includes a controllable contactor switch. A boost charging module includes a DC-DC boost converter, a low-voltage power input line, a boost switch and a boost controller. The DC-DC boost converter is electrically connected to the low-voltage power input line via activation of the boost switch. The DC-DC boost converter connects to the positive rail. A low-voltage electrical connector is electrically connected to the low-voltage power input line of the DC-DC boost converter. The boost controller detects low-voltage power from the low-voltage electrical connector, detects that the controllable contactor switch, closes the boost switch, and controls the DC-DC boost converter to convert the low-voltage power on the low-voltage power input line to high-voltage power to charge the high-voltage battery.

Method and apparatus for charging a high-voltage battery assembly

A power inverter includes a multi-phase inverter circuit electrically connected to positive and negative conductors of the high-voltage bus. A bi-stable switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus, and a capacitor is electrically connected between the positive and negative conductors of the high-voltage bus. First and second trigger circuits are in communication with a gate of the bi-stable switch, and first and second contactors are controllable to electrically connect a respective one of the positive and negative conductors of the high-voltage bus to the high-voltage DC power source. The bi-stable switch is controllable to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal from one of the first and second high-voltage DC contactor circuits.

Apparatus for discharging a high-voltage bus

An electrical system includes a voltage bus, battery pack, power inverter module (PIM), electric machine, first contactor, and controller. The PIM is connected to the battery pack and has a capacitor, voltage sensor, and semiconductor switches. The electric machine having phase legs with a corresponding phase winding and resistive path. The first contactor connects the PIM to a positive rail of the bus. The controller opens the first contactor in response to a power-off event, commands a discharge of the capacitor through the resistive paths, diagnoses a state of health (SOH) of the first contactor using a first threshold decay rate of the capacitor output voltage upon opening the first contactor, and executes a control action with respect to the electrical system using the diagnosed SOH. The three possible SOH are unhealthy/hard-welded contactor, unhealthy/soft-welded contactor, and healthy/normally-functioning contactor condition. A vehicle and method are also disclosed.

Method and system for diagnosing contactor health in a high-voltage electrical system

A discharge circuit for a high-voltage bus that is electrically connected to a high-voltage DC power source is described. The discharge circuit includes a discharge switch electrically connected in series with a discharge resistor between positive and negative conductors of the high-voltage bus, and the discharge switch includes a gate. A bi-stable switch includes a control gate, an input line that is electrically connected to the high-voltage bus and an output line that is electrically connected to the gate of the discharge switch. A trigger device is in communication with the control gate of the bi-stable switch. The input line of the bi-stable switch is electrically connected to the high-voltage bus, and the discharge switch is controllable to a closed state to provide an electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal.

A power inverter including a multi-phase inverter circuit is electrically connected to a high-voltage DC power source, and includes a capacitor electrically connected between positive and negative conductors of a high-voltage bus. A normally-ON discharge switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus. The discharge switch includes a control gate, wherein the control gate of the discharge switch is in communication with an ignition switch. The discharge switch is controllable to an open state between the positive and negative conductors of the high-voltage bus when the ignition switch is in an ON state. The discharge switch achieves a closed state to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus when the ignition switch is in an OFF state.

A sensor for detecting leaked cooling fluid in a battery pack or container. The sensor is part of a sensor wire, where one end of the wire is electrically coupled to the positive terminal or the negative terminal of the battery pack and the other end of the wire is positioned at a location where the leaked cooling fluid may accumulate. A fault isolation detection circuit monitors a voltage output from the sensor and determines that there is a cooling fluid leak if the measured voltage potential is greater than a predetermined voltage threshold.

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West Bloomfield, MI, United States of America

Andrew J Namou