Lear Corporation

Sergio Martinez Porras

Adria Marcos Pastor

Victor Saborido Rodriguez

Antonio Martinez Perez

Cesar Ruano Alvarez

Josep Maria Bosque Moncusi

Joel Aaron Storr

An on-board battery charger (OBC) of an electric vehicle (EV) receives AC electrical power from a charge station and outputs a DC output current for charging a traction battery of the EV. In response to transients in the AC electrical power while the OBC is receiving the AC electrical power from the charge station and outputting the DC output current, a controller controls the OBC to (i) stop processing the AC electrical power from the charge station and reduce the DC output current and (ii) after the transients have passed, resume processing the AC electrical power from the charge station and increase the DC output current. At a zero-crossing event of the AC electrical power after the transients have passed, the OBC is controlled to resume processing the AC electrical power from the charge station and increase the DC output current.

Method and system for controlling on-board battery charger of electric vehicle to accommodate transients in supply voltage

An on-board battery charger (OBC) includes a converter (e.g., a DC/DC converter) and a controller. An output port of the converter is connectable to a battery (e.g., a traction battery of an electric vehicle (EV)) via a voltage network (e.g., a high-voltage (HV) network of the EV). The converter converts an input power into an output power and outputs the output power onto the voltage network for charging the battery. The controller, upon detecting a transitory disconnection in the voltage network, controls the converter to stop converting the input power into the output power. In stopping the converter, the controller stops the converter prior to a corresponding reconnection in the voltage network. The controller may detect the transitory disconnection upon detecting a switching frequency of a power switch of the converter decreasing below a pre-defined threshold as the switching frequency decreases due to effects of the transitory disconnection.

Method and system for protecting on-board battery charger against transitory disconnections in high-voltage network

An on-board battery charger (OBC) includes (i) rail circuits having respective rail controllers and (ii) a main controller. The rail controllers sample voltages supplied to their rail circuits and transmit a fault signal to the main controller upon a comparison between a sampled voltage and a threshold being affirmative of an improper voltage condition (overvoltage or undervoltage) of the sampled voltage. The main controller controls all of the rail controllers to stop operation of all of the rail circuits in response to receiving the fault signal from any of the rail controllers. In a variation, the main controller samples the voltages supplied to the rail circuits and stops operation of all of the rail circuits upon a comparison between a sampled voltage and the threshold being affirmative.

Method and system for voltage-based detection of loss of neutral between on-board charger and multi-phase mains supply

An on-board charger is provided with a first stage for converting an alternating current (AC) voltage from an external power supply to a direct current (DC) voltage. A capacitor is coupled to the first stage to receive the DC voltage and to provide a DC-Link voltage. A second stage is coupled to the capacitor to boost the DC-Link voltage and to supply the boosted DC-Link voltage to charge a battery. A processor is programmed to adjust the DC-Link voltage between a first setpoint and a second setpoint based on a battery voltage value.

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Valls, Spain

Sergio Martinez Porras