Tesla Motors, Inc.

Tesla, Inc.

Troy Adam Nergaard

Nicholas Robert Kalayjian

Jeffrey Brian Straubel

Jean-Pierre Krauer

Scott Ira Kohn

Kristoffer John Donhowe

Joshua Willard Ferguson

Daryl Zalan

Christopher Hugo Van Dyke

Ian Craven

Martin Sukup

Arthur Joseph Hebert

Andrew David Baglino

Warwick Ka Kui Wong

Andrew Dai

Vineet Haresh Mehta

Anil Paryani

Heath Fred Hofmann

An inter-protocol charging adapter for equipment to be charged via a bus includes: first connectors corresponding to a first charging protocol that requires the bus to be energized before the equipment closes onto the bus; second connectors corresponding to a second charging protocol that does not energize the bus before the equipment closes onto the bus; and a boost converter coupled to the bus and to at least one of the second connectors, wherein the boost converter uses energy from the second connector to energize the bus before the equipment closes onto the bus.

Inter-protocol charging adapter

An apparatus and method efficiently integrating inductive and conductive charging systems, including embodiments directed towards enabling user selection of either, or both, of conductive and inductive charging. Conductive charging and inductive charging both have, in certain contexts or when judged by different criteria, advantages over the other. Systems and methods relying on one or the other would not have as wide-spread value to a user with opportunities to access both types of charging modalities.

Integrated inductive and conductive electrical charging system

The apparatus for charging an energy storage system (ESS) from an AC line voltage includes a boost stage for converting the AC line voltage to a first ESS charging voltage; an isolation stage, coupled to the boost stage, for converting the first ESS charging voltage to a second ESS charging voltage with the second ESS charging voltage less than the first ESS charging voltage, the isolation stage removing a common mode current between the ESS and the boost stage; a configurator, responsive to a control signal, to set a direct communication of the first ESS charging voltage to the ESS in a bypass mode and to open the direct communication of the first ESS charging voltage to the ESS in an isolation mode; and a controller, coupled to the configurator, for setting the modes responsive to a battery voltage, a peak of the AC line voltage, and a total leakage current at an input of the AC line voltage, the controller asserting the control signal to the configurator.

Charging efficiency using selectable isolation

A battery charging station is provided that includes a plurality of charge ports, a plurality of power stages where each power stage includes an AC to DC converter and where each power stage provides a portion of the charging station's maximum available charging power, a switching system that is used to couple the output of the power stages to the charging ports, a system monitor that determines current charging station and vehicle conditions, and a controller that controls operation of the switching system in accordance with a predefined set of power distribution rules and on the basis of the current charging station and vehicle conditions. Current charging station and vehicle conditions may include vehicle arrival time, usage fees, vehicle and/or customer priority information, battery pack SOC, and/or intended departure time.

Multiport vehicle DC charging system with variable power distribution according to power distribution rules

A door latching system for the door covering the charge port of an electric vehicle, or for the door covering the fuel filler port of a conventional vehicle, is provided. The door latching system is comprised of a ferromagnetic member attached to an interior surface of the door, and a latching assembly integrated into the port housing, where the latching assembly includes an assembly case, an electromagnet, and a permanent magnet that maintains the door in a closed position when the electromagnet is not energized and releases the door when the electromagnet is energized. The latching assembly may include a magnetic flux sensor that monitors when the port door is open or closed. The magnetic flux sensor may be coupled to a system controller that performs a preset response when the magnetic flux sensor determines that the door is open.

Charge port door with electromagnetic latching assembly

A method of distributing charging power among a plurality of charge ports of a battery charging station is provided, where the battery charging station includes a plurality of power stages where each power stage includes an AC to DC converter and provides a portion of the charging station's maximum available charging power, the method comprising the steps of (i) monitoring battery charging station conditions and operating conditions for each charging port; (ii) determining current battery charging station conditions, including current operating conditions for each charging port; (iii) determining power distribution for the battery charging station and the charging ports in response to the current battery charging conditions and in accordance with a predefined set of power distribution rules; and (iv) coupling the power stages to the charging ports in accordance with the power distribution.

Method of operating a multiport vehicle charging system

A charging system and method that improves utilization of available AC power during onboard charging of energy storage systems of electric vehicles. An onboard charging method for an energy storage system of an electric vehicle, the method using an AC power source, includes a) establishing a maximum DC charging current for the energy storage system responsive to a control signal indicating real-time available current/power from the AC source; and b) controlling a charging system to provide an actual DC charging current, up to the maximum DC charging current, to the energy storage system.

AC current control of mobile battery chargers

A contamination cleaner for a socket of a charging connector used with a charging station for an electric vehicle wherein the charging connector mates to a charging coupler of the electric vehicle during charging includes a housing mechanically configured generally similarly to the charging coupler enabling the housing to mechanically mate to the charging connector; and a cleaning contact, coupled to the housing and complementary to the socket, for engaging the socket and removing surface contaminants from the socket whenever the housing mechanically mates to the charging connector.

Cleaning feature for electric charging connector

A fuel delivery system and method of use are provided that may be used to open the door covering the charge port of an electric vehicle, or the door covering the fuel filler port of a conventional vehicle. The system includes a fuel coupler (e.g., a charging connector or a gas nozzle) designed to transfer fuel from the source to the vehicle via the vehicle's fuel port. The fuel coupler includes a switch that when toggled, causes a control signal to be wirelessly transmitted over a short distance. Upon receipt of the control signal by a receiver integrated into a vehicle that is in close proximity to the fuel port, an unlatching actuator within the vehicle unlatches the port door, thereby allowing it to open and provide port access.

Fuel coupler with wireless port door unlatching actuator

A port door unlatching system is provided that may be used to open the door covering the charge port of an electric vehicle, or the door covering the fuel filler port of a conventional vehicle. The system includes a fuel delivery subsystem with a fuel coupler (e.g., a charging connector or a gas nozzle) designed to transfer fuel from the source to the vehicle via the vehicle's fuel port. The fuel coupler includes a switch that when toggled, causes a control signal to be wirelessly transmitted over a short distance. Upon receipt of the control signal by a receiver integrated into a vehicle that is in close proximity to the fuel port, an unlatching actuator within the vehicle unlatches the port door, thereby allowing it to open and provide port access.

Vehicle port door with wirelessly actuated unlatching assembly

A method of charging a rechargeable battery pack installed in an electric vehicle is provided in which the charging system includes a switching circuit that is operable in at least a first mode and a second mode. In the first mode the switching circuit couples the power supply and an external power source to both a heater and the charging circuit, the heater providing a voltage divider circuit within the charging circuit. In the second mode the switching circuit couples the power supply and the external power source only to the charging circuit, bypassing the heater.

Method of operating a recharging system utilizing a voltage dividing heater

A voltage converter for charging an energy storage module from an alternating current line voltage, includes a first charging stage, coupled to the energy storage module, converting the line voltage to a first rectified direct current module charging voltage communicated to the energy storage module, the first rectified direct current module charging voltage greater than the line voltage, the first charging stage including an inductance for communicating a first charging current to the energy storage module; a second charging stage, switchably coupled serially with the first charging stage, down-converting the alternating current line voltage to a second rectified direct current module voltage, the second rectified direct current module voltage less than the first rectified direct current module charging voltage, wherein the second charging stage produces a second charging current not greater than the first charging current; and a controller for selectably switching the second charging stage serially with the first charging stage when the line voltage has a peak value greater than a predefined relationship to a voltage of the energy storage module wherein the second charging stage communicates the second charging current to the energy storage module through the inductance.

Trickle charger for high-energy storage systems

An apparatus comprising a rechargeable battery pack installed in an electric vehicle, a power supply coupled to the rechargeable battery pack, the power supply operable to provide a charge voltage to perform charging operations on the rechargeable battery pack, a heater to heat a fluid to be circulated through the rechargeable battery pack, the fluid thermally coupled to a plurality of battery cells within the rechargeable battery pack, a switching circuit, the switching circuit coupled to the heater and to the power supply, the switching circuit operable in a first mode to couple the source of electrical power to the heater without coupling the source of electrical power to the rechargeable battery pack, the switching circuit operable in a second mode to couple a source of electrical power external to the electric vehicle to the power supply to form a recharging circuit in order to perform charging operations on the rechargeable battery pack.

Voltage dividing vehicle heater system and method

A voltage estimation system for motor control feedback is described. The system may include one or more control modules which may generate voltage commands. An overmodulation or 'clipping' module receiving a voltage command can generate a clipped voltage. Rather than measuring directly, a voltage estimator may estimate the clipped voltage based on the duty cycle command to the inverter. This estimated voltage may then be used by a flux estimator to estimate a flux value. Other embodiments are described and claimed.

Voltage estimation feedback of overmodulated signal for an electrical vehicle

An apparatus including a rechargeable battery pack installed in an electric vehicle, the rechargeable battery pack coupled to a power supply, the power supply operable to provide a charge voltage to perform charging operations on the battery pack, a heating element to heat a fluid to be circulated through the rechargeable battery pack, a comparator circuit to compare a battery voltage of the rechargeable battery pack to a line source voltage, the comparator circuit operable to compare the battery voltage to the line source voltage and to provide an output signal when the battery voltage is less than a line voltage offset value, and a control circuit coupled to receive the output signal of the comparator, and to couple the line source voltage to the power supply, an to bypass the heating element if the comparator is not providing the output signal.

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San Francisco, CA, United States of America

Troy Adam Nergaard