Lear Corporation

Victor Saborido Rodriguez

Adria Marcos Pastor

Antonio Martinez Perez

Sergio Martinez Porras

Josep Maria Bosque Moncusi

Cesar Ruano Alvarez

Edgar Zahino Andres

Alberto Martinez Ramirez

Luis Roda Cornejo

Joel Aaron Storr

Josep Maria Bosque

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 (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.

Vehicle on-board charger with variable DC-link voltage

A converter module is provided with a first power delivery circuit, a second power delivery circuit, and a controller. The first power delivery circuit supplies current from a first direct current (DC) source to a resonant stage in a first direction. The first power delivery circuit comprises at least two first switches. The second power delivery circuit supplies the current from the first DC source to the resonant stage in a second direction, opposite the first direction. The controller includes memory, and a processor that is programmed to: enable the first power delivery circuit and the second power delivery circuit alternately to provide power as a periodic waveform to the resonant stage; and disable the at least two first switches individually in a sequence to generate a phase shift in the periodic waveform and to disable the first power delivery circuit.

Converter module with phase shift

An on-board charger (OBC) for charging a traction battery of an electric vehicle includes a primary phase, a secondary phase, and a pre-charge circuit. Each phase includes a circuit having an input and an output. The primary phase circuit input is connectable to a mains supply to connect the primary phase to the mains supply. The secondary phase circuit input has an input capacitor. The pre-charge circuit is connected between the circuit outputs and is switchable between an opened state in which the pre-charge circuit disconnects the circuit outputs and a closed state in which the pre-charge circuit connects the circuit outputs. When the pre-charge circuit is in the closed state, an electrical current may flow through the pre-charge circuit from the primary phase circuit output to the secondary phase circuit output and through the secondary phase circuit to the input capacitor to charge the input capacitor.

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Valls, Spain

Victor Saborido Rodriguez