Electrical power supply device and method of operating same

This application is a continuation application and claims the benefit of co-pending U.S. patent application Ser. No.16/203,717, filed Nov. 28, 201816/006,463, filed Jun. 12, 2018, which was a continuation-in-part application and claimed the benefit patent application Ser. No. 15/954,851, filed Apr. 17, 2018, the entire disclosure of each of which is hereby incorporated herein by reference.

The invention generally relates to an electrical power supply device and method of operating the electrical power supply device.

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

The Universal Serial Bus (USB) has evolved from a data interface capable of supplying limited power to a primary provider of power with a data interface. Today many devices charge or get their power from USB ports contained in laptops, cars, aircraft or even wall sockets. USB has become a ubiquitous power socket for many consumer devices such as cellular telephones, digital media players and/or other hand-held devices. Users utilize USB to fulfil their requirements not only in terms of data but also to provide power to, or charge, their devices simply, often without the need to load a driver, in order to carry out “traditional” USB functions.

The USB Power Delivery (PD) Specification enables the maximum functionality of USB by providing more flexible power delivery, e.g. for battery charging, along with data over a single cable. Its aim is to operate with and build on the existing USB ecosystem. The USB Power Delivery Specification 3.0 is published by the USB Implementer's Forum, Inc and is incorporated by reference herein.

In order to meet stringent fuel economy and emission standards, automotive original equipment manufacturers (OEMs) have included start-stop technology in their vehicles that automatically shuts down and restarts the internal combustion engine to reduce the amount of time the engine spends idling, thereby reducing fuel consumption and emissions of the vehicle.

OEMs have imposed requirements for a USB PD device powered by the vehicle battery requires it to continue to supply power to the consumer USB device during “Start/Stop” transients in which the vehicle battery voltage temporarily dips down to as low as 6 volts to simulate the vehicle cranking during a warm start. During this transient, the USB PD device is expected to continue to function with no disruption to the consumer experience. Supplying a consistent power level during the transient will cause the current input to the PD device to rise to levels that may exceed current limits of the wiring, connectors, and/or circuit protection devices, e.g. fuses, circuit breakers, of the PD device that would cause a disruption of the consumer experience, e.g. opening a fuse and thereby causing a shutdown of the PD device.

Some original equipment vehicle manufacturers (OEMs) monitor the power being supplied by the vehicle's electrical power system and inhibit the start-stop controller if the power supplied exceeds a power threshold.

A proposed innovative solution is to provide a signal from the vehicle to the USB PD device to indicate the power state of the vehicle. During the normal vehicle run mode the vehicle voltage is expected to be typically in the 12-14 volt range and a buck-boost DC-DC converter can generate a higher voltage output that has a greater voltage than the vehicle voltage that can be used by the consumer charging device in a “fast charge” mode. When the vehicle enters or intends to enter the stop/start mode, i.e. the vehicle has stopped moving and automatically turns off the engine, the change in mode is communicated by a signal from the vehicle to a controller in the USB PD device and the USB PD device then renegotiates the charging contact with the consumer device to provide a lower output voltage for “normal” charging operation. When the car subsequently experiences a crank cycle transient, the buck converter is able to maintain the lower output voltage without exceeding current limits and without interrupting the charging session. After the engine starts and returns to the run mode, the USB PD device is again notified via another signal and returns to the higher voltage output.

1 FIG. 10 12 10 12 10 14 10 illustrates an electrical power supply device, e.g. a Universal Serial Bus (USB) power delivery (PD) device, hereinafter referred to as the PD devicethat is designed for use in a motor vehicle. The PD devicemay be used to support battery charging of USB enabled devices in the vehicle(not shown). The PD deviceincludes a boost-buck DC-DC power convertor, hereinafter referred to as the DC convertor, that receives an input voltage from a vehicle's electrical system. In other embodiments of the invention, the PD devicemay be a buck only DC-DC power convertor. The output voltage can by one of at least two different voltages, a higher voltage, e.g. a 20-volt output to support a fast USB charge rate, or a lower voltage, e.g. a 5-volt output to support a normal USB charge rate.

10 16 14 16 The PD devicealso includes a device controllerthat is in communication with the DC convertor. The device controllerhas one or more processors and memory. The processors may be microprocessors, application specific integrated circuits (ASIC), or built from discrete logic and timing circuits (not shown). Software instructions that program the processors may be stored in a non-volatile (NV) memory device (not shown). The NV memory device may be contained within the microprocessor or ASIC or it may be a separate device. Non-limiting examples of the types of NV memory that may be used include electrically erasable programmable read only memory (EEPROM), masked read only memory (ROM), and flash memory.

10 18 10 12 The PD devicealso includes interface circuitry, such as a controller area network (CAN) transceiver, a local interconnect network (LIN) transceiver, a USB transceiver, and/or an input voltage detection circuit, e.g. an analog/digital convertor circuit, to allow the PD deviceto establish electrical communication with other devices within the vehicle.

10 20 16 14 16 20 16 14 16 20 22 22 The PD deviceis in communication with a start-stop controllervia the CAN transceiver or the LIN transceiver. The memory further includes instructions which cause the device controllerto command the DC convertorto output the higher output voltage in accordance with the device controllerreceiving a run signal from the start-stop controller. The reception of the run signal causes the device controllerto command the DC convertorto output the lower output voltage in accordance with the device controllerreceiving a stop signal from the start-stop controller. The run signal indicates that the IC engineis running, therefore the input voltage will remain equal to or greater than the threshold voltage. The stop signal indicates that the IC engineis not running and that the input voltage may drop to less than the threshold voltage, e.g. during a cranking transient.

10 24 20 16 14 16 24 24 20 16 14 16 24 24 20 In another embodiment, the PD deviceis disposed within a USB port that is in communication with a USB hubthat is in communication with the start-stop controller. The memory includes instructions which cause the device controllerto command the DC convertorto output the higher output voltage in accordance with the device controllerreceiving a first USB signal from the USB hubindicating that the USB hubhas received a run signal from the start-stop controllerand which cause the device controllerto command the DC convertorto output the lower output voltage in accordance with the device controllerreceiving a second USB signal from the USB hubindicating that the USB hubhas received a stop signal from the start-stop controller.

10 16 10 16 16 14 16 14 In yet another embodiment, the PD deviceincludes an input voltage detection circuit that is in communication with the vehicle power supply, e.g. vehicle battery (not shown) and the device controller. The input voltage detection circuit is configured to determine the input voltage to the PD devicefrom the vehicle battery and transmit that information to the device controller. The memory includes additional instructions which cause the device controllerto command the DC convertorto output the higher output voltage when the input voltage detection circuit determines that the input voltage is greater than a threshold voltage, e.g. 9.5 or 10 volts and which cause the device controllerto command the DC convertorto output the lower output voltage when the input voltage detection circuit determines that the input voltage is less than the threshold voltage.

2 FIG. 100 10 14 16 20 100 illustrates a methodof operating the PD devicehaving the DC convertorand the device controllerand in communication with the start-stop controller. The methodincludes the following steps:

102 10 20 STEP, RECEIVE A SIGNAL FROM THE START-STOP CONTROLLER, includes the PD devicereceiving a signal from the start-stop controller;

104 16 STEP, DETERMINE WHETHER THE SIGNAL IS A RUN SIGNAL OR A STOP SIGNAL, includes the device controllerdetermining whether the signal is a run signal or a stop signal;

106 10 14 16 STEP, PRODUCE A FIRST OUTPUT VOLTAGE, includes the PD deviceproducing the higher output voltage via the DC convertorin accordance with the device controllerdetermining that the signal is the run signal; and

108 10 14 16 STEP, PRODUCE A SECOND OUTPUT VOLTAGE, includes the PD deviceproducing a second output voltage via the DC convertorwhich is less than the first output voltage in accordance with the device controllerdetermining that that the signal is the stop signal.

10 12 20 10 10 12 10 20 10 According to a particular embodiment, if the PD devicehas negotiated a PD contract with a consumer device (not shown) at 100 watts i.e. the output voltage is 20 volts and current capacity is 5 amperes and a start-stop event occurs, in the vehicle, i.e. the start-stop controllersends a stop signal, the PD devicewill change the power negotiation from 100 watts to 15 watts, i.e. output voltage is 5 volts and current capacity is 3 amperes, thereby reducing power required to be supplied to the PD deviceby the vehicleand reducing the current drawn by the PD deviceand staying within the limits of the circuits current protection devices. Per the USB PD specifications, the consumer device will select the new 15-watt capability. After the stop-start event ends, i.e. the start-stop controllersends a run signal, the PD devicewill renegotiate 100-watt capability and the consumer device will choose highest power needed.

10 100 10 10 12 10 20 Accordingly, an electrical power supply device, e.g. a USB PD device, and a methodof operating such a device is provided. The device provides the benefit of a USB PD devicethat is capable of uninterrupted supply of power from the PD deviceto a consumer USB device during a start-stop event in a vehicle. This USB PD devicemay also provide the benefit of reducing or “shedding” electrical load from the vehicle's electrical system by reducing, but not discontinuing, the power supplied to the USB consumer device, e.g. reducing power supplied from 100 watts to 15 watts, which may allow the start-stop controllerto enter the start-stop mode.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments.

Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.