US 12,403,777 B2
Power control system for DC-DC converter and inverter pre-charging and shutdown
Chunhao J. Lee, Troy, MI (US); Lei Hao, Troy, MI (US); Dongxu Li, Troy, MI (US); and Suresh Gopalakrishnan, Troy, MI (US)
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Nov. 30, 2021, as Appl. No. 17/538,920.
Prior Publication US 2023/0166633 A1, Jun. 1, 2023
Int. Cl. B60L 50/51 (2019.01); B60L 1/00 (2006.01); B60L 58/18 (2019.01); H02M 1/00 (2006.01); H02M 1/36 (2007.01); H02M 3/158 (2006.01); H02M 7/5387 (2007.01); G01R 19/165 (2006.01); H02J 7/34 (2006.01); H02M 1/32 (2007.01)
CPC B60L 50/51 (2019.02) [B60L 1/003 (2013.01); B60L 58/18 (2019.02); H02M 1/0003 (2021.05); H02M 1/36 (2013.01); H02M 3/158 (2013.01); H02M 7/5387 (2013.01); B60L 2210/10 (2013.01); B60L 2210/42 (2013.01); B60L 2240/527 (2013.01); B60L 2240/547 (2013.01); G01R 19/16538 (2013.01); H02J 7/34 (2013.01); H02J 7/345 (2013.01); H02M 1/32 (2013.01); H02M 1/322 (2021.05)] 17 Claims
OG exemplary drawing
 
1. A power control system for a propulsion system of a vehicle, comprising:
an energy storage system including a precharge circuit and one or more battery packs;
a DC-DC converter connected to the energy storage system and including a first capacitor, a first plurality of power switches and an inductor;
a power inverter module connected to the DC-DC converter and including a second capacitor and a second plurality of power switches; and
a controller configured to:
pre-charge the first capacitor of the DC-DC converter and the second capacitor of the power inverter module; and
control operating modes of the DC-DC converter and the power inverter module,
wherein the controller is configured to at least one of
after pre-charging the first capacitor of the DC-DC converter, control an output voltage of the DC-DC converter to ramp up voltage across the second capacitor of the power inverter module to pre-charge the second capacitor, and
close a bidirectional bypass switch and concurrently pre-charge the first capacitor and the second capacitor, the bidirectional bypass switch being connected between the power inverter module and the energy storage system, and
wherein the controller is configured to
when stopping the propulsion system, ramp down the output voltage of the DC-DC converter to the voltage less than a first predetermined threshold,
when the output voltage of the DC-DC converter is less than the first predetermined threshold, transition the power inverter module from a run mode to a stop mode and the DC-DC converter from a run mode to a standby mode, and
disconnect the energy storage system and, when an input voltage of the DC-DC converter is less than a second predetermined threshold, transition the propulsion system from an active mode to a stop mode.