Automotive vehicle charge port with fault interrupt circuit

BACKGROUND

0001United States Patent Number <patcit id="pcit0001" dnum="US6788504B"><text>6,788,504</text></patcit> to Vanderkolk discloses a mobile system for use in supplying AC power to different types of electrical loads including those having grounded neutrals as well as those having neutrals that are electrically isolated from ground. The system includes a GFCI circuit and can be switched between a first mode, in which the circuit provides AC power with ground fault protection for those loads having ungrounded (isolated) neutrals, and a second mode, in which the GFCI is deactivated so that it will not experience false tripping due to the intentional grounding of the neutral at the load. Both single and multi-phase systems are disclosed which can be incorporated into a vehicle, towed trailer, or portable generator. The system may be used to provide AC power to various types of electrical loads at locations where public utility power is not readily available.

0002United States Patent Number <patcit id="pcit0002" dnum="US6052266A"><text>6,052,266</text></patcit> to Aromin discloses a ground fault circuit interrupter (GFCI) that interrupts the flow of current through a pair of lines extending between a source of power and a load. The GFCI includes a circuit breaker having a switch located in one of the pair of lines. The switch has a first position in which the source of power in its associated line is not connected to the load and a second position in which the source of power in its associated line is connected to the load. A relay circuit is coupled to the switch selectively positioning the switch in either the first or second position. The relay circuit includes a solenoid, which operates in either an energized or de-energized state. The GFCI also includes a booster circuit for selectively supplying a first voltage through the switch and to the solenoid, which is sufficient to cause the solenoid to switch from its de-energized state to its energized state. A power supply circuit supplies a second voltage to the solenoid, which is less than the first voltage. The second voltage is sufficient to maintain the solenoid in its energized state after bering initially energized by the first voltage. A latch circuit operable in first and second bi-stable states allows the solenoid to switch from its de-energized state to its energized state. A fault detecting circuit detects the presence of a fault condition in at least one of the lines and causes the latch circuit to latch in its second bi-stable state upon detection of the fault condition.

0003United States Patent Number <patcit id="pcit0003" dnum="US5786971A"><text>5,786,971 to Chan et al.</text></patcit> discloses a ground fault protection circuit for plural loads connected across a power source with plural branches that can be used where the loads are unbalanced. Each branch includes a ground fault circuit interrupter device that has a common line for the electronics of the GFCI separate from the neutral line from the power source to the load, where the common lines for the electronics for the ground circuit interrupter devices in each branch are connected to a common point. The ground fault protection circuit employs plural ground fault circuit interrupter devices and eliminates nuisance tripping. The common line for the electronics for a GFCI is routed through the core of the current sensing transformer of the GFCI. The separate neutral line for the electronics, connecting the common lines for the electronics for plural GFCI devices and routing the common lines for the GFCI electronics through the core of the transformer of each GFCI, eliminate improper GFCI operation due to unbalanced loading. The ground fault protection circuit may be used for a three phase power source.

0004<patcit id="pcit0004" dnum="WO2006121142A"><text>WO 2006/121142</text></patcit> is regarded as the closest prior art and shows an automotive vehicle relevant for the present invention.

SUMMARY

0005An automotive vehicle includes a battery charger disposed within the vehicle, and a charge port integrated with the vehicle. The charge port includes electrical contacts configured to receive electrical power from an electric grid, and a fault interrupt circuit electrically connected with the electrical contacts and the battery charger.

0006An automotive vehicle includes a charge port integrated with the vehicle. The charge port includes electrical contacts configured to receive electrical power from an electric grid, and a fault interrupt circuit electrically connected with the electrical contacts.

0007An automotive power system includes a power storage unit, a power converter electrically connected with the power storage unit, and a charge port integrated with the vehicle. The charge port includes electrical contacts configured to receive electrical power from a remote power source, and a fault interrupt circuit. The fault interrupt circuit is electrically connected with the power converter and the electrical contacts.

0008While example embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the invention. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

0009<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">FIGURE 1</figref> is a schematic diagram of an embodiment of an automotive vehicle.</li><li><figref idref="f0001">FIGURE 2</figref> is a schematic diagram of another embodiment of an automotive vehicle.</li></ul>

DETAILED DESCRIPTION

0010A variety of street- and highway-worthy electric and combination electric/fossil fuel vehicles are becoming available to consumers. New and proposed legislation in several regions around the United States calls for increasing deployment of electric vehicles as a way to reduce air pollution. Certain states have adopted similar requirements. Additionally, the Clean Air Act Amendments of 1990 and the National Energy Policy Act of 1992 regulate public and private purchases of clean-fuel vehicles and alternatively fuelled vehicles, respectively. Electric vehicles fulfill both of those requirements. As a result, electric vehicle charging may be occurring in all occupancies, including residential, commercial, retail, and public sites.

0011Article 625 of the National Electric Code (NEC) sets forth installation requirements for typical hardwired conductive connections of battery charging equipment, as well as the safety concerns of new "smart" inductive coupling connections of battery charging equipment. In particular, this article covers the wiring methods, equipment construction, control and protection, and equipment locations for automotive-type vehicle charging equipment. The stated intent of Article 625 is to prevent users of electrical equipment associated with the vehicle charging system from being exposed to energized live parts and to provide a safe vehicle charging environment.

0012Article 625 requires that the overall length of an electric vehicle supply equipment cable shall not exceed 25 ft. unless equipped with a cable management system that is listed as suitable for the purpose. Additionally, Article 625 requires that electric vehicle supply equipment shall have a listed system of protection against electric shock of personnel. Where cord-and-plug-connected electric vehicle supply equipment is used, an interrupting device of a listed personnel protection system shall be provided and shall be an integral part of the attachment plug or shall be located in the power supply cable not more than 12 in. from the attachment plug.

0013If non-conforming cord-and-plug-connected electric vehicle supply equipment is used to charge a vehicle (in concert with a non-GFI outlet), electric shock may be experienced.

0014Referring now to <figref idref="f0001">Figure 1</figref>, an embodiment of an automotive vehicle 10, e.g., hybrid electric, electric, etc., includes a traction battery 12, electric machine 14, and battery charger 16. As apparent to those of ordinary skill, the electric machine 14 may convert electrical power from the traction battery 12 to motive power to move the vehicle 10.

0015The battery charger 16 may include a bridge rectifier 18, boost regulator 20, buck regulator 22 and microprocessor 24. The bridge rectifier 18 is electrically connected with the boost regulator 20, and converts alternating current input to direct current output. The boost regulator 20 is electrically connected with the buck regulator 22. The microprocessor 24 may control the boost and buck regulators 20, 22 in a known fashion. For example, the microprocessor 24 may control the boost regulator 20 to regulate the direct current output by the bridge rectifier 18 for power factor correction, etc. The circuitry of the bridge rectifier 18, boost regulator 20 and buck regulator 22 may take any suitable form.

0016The embodiment of vehicle 10 further includes a charge port 26 (charging receptacle, etc.) The charge port 26, in the embodiment of <figref idref="f0001">Figure 1</figref>, includes electrical contacts 28 and a fault interrupt circuit 30 (e.g., GFI, GFIC, CCID, etc.) The electrical contacts 28 are arranged in a known fashion, and may be electrically connected (e.g., plugged-in) with an electrical wall outlet (serviced by an electrical grid) via a charging cable 32 that includes a line 34, neutral 36 and ground 38.

0017The fault interrupt circuit 30 (which may take any suitable form) is electrically connected between the electrical contacts 28 and the bridge rectifier 18 of the battery charger 16. The fault interrupt circuit receives the line, neutral and ground voltages from the electrical contacts 28, grounds the ground voltage to, for example, the vehicle chassis (not shown), and passes the line and neutral voltages to the bridge rectifier 18 of the battery charger 16. Locating the fault interrupt circuit 30 within the charge port 26 may improve the ability of the fault interrupt circuit 30 to detect ground faults in the vehicle 10.

0018As apparent to those of ordinary skill, if the fault interrupt circuit 30 detects a ground fault on the vehicle 10, it can disconnect the power to the vehicle 10 at the charge port 26 in a known fashion.

0019Referring now to <figref idref="f0001">Figure 2</figref>, numbered elements that differ by 100 relative to <figref idref="f0001">Figure 1</figref> may have similar descriptions to the numbered elements of <figref idref="f0001">Figure 1</figref>. The embodiment of the appended claims of an automotive vehicle 110 includes a traction battery 112, electric machine 114, power converter 116, and charge port 126. The power converter 116 in the embodiment of the appended claims of <figref idref="f0001">Figure 2</figref> includes an inverter. As such, electrical power stored by the traction battery 112 may be passed through the inverter and to the charge port 126.

0020The charge port 126, in the embodiment of the appended claims of <figref idref="f0001">Figure 2</figref>, includes a fault interrupt circuit as described with reference to <figref idref="f0001">Figure 1</figref>. In other embodiments, the charge port 126 may lack a fault interrupt circuit. Other arrangements are, of course, also possible.

0021A fault interrupt circuit 130 has been electrically connected between the power converter 116 and the charge port 126. This additional fault interrupt circuit 130 protects, for example, the power converter 116, traction battery 112, and electric machine 114 from ground faults between the charging cable 132 and earth ground (the chassis of the vehicle 110).

0022While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the scope of the invention.