Unitary vehicle on-board charger and generator

1. A unitary on-board charger and generator for an electric vehicle, comprising:

a charging circuit including:

a diode bridge rectifier connected to an AC power source,

a power factor correction converter connected between the diode bridge rectifier and a filtering capacitor, and

a bi-directional DC/DC converter connected between the filtering capacitor and a traction battery,

a generating circuit including:

a three-phase inverting circuit having a first output leg, a second output leg, and a third output leg, the three-phase inverting circuit being connected to the filtering capacitor and the bi-directional DC/DC converter,

a first three-phase inductive coil connected to the first output leg, a second three-phase inductive coil connected to the second output leg, and a third three-phase inductive coil connected to the third output leg connected, and

a plurality of output capacitors connected to the first three-phase inductive coil, the second three-phase inductive coil, and the third three-phase inductive coil; and

a bridge capacitor and a control switching element connected between the charging circuit and the generating circuit.

2. The unitary on-board charger and generator of claim 1 , wherein the three-phase inverting circuit includes a plurality of switching elements.

3. The unitary on-board charger and generator of claim 2 , wherein the power factor correction converter includes a charging inductor coil, a charging solid-state switching element, a charging diode, and a mode switching element parallelly connected to the charging diode.

4. The unitary on-board charger and generator of claim 3 further comprising:

a controller operable to:

disengage the mode switching element and the control switching element;

cycle the charging solid-state switching element at a predetermined frequency;

disengage one or more of the plurality of switching elements; and

control the bi-directional DC/DC converter to convert an AC energy received by the AC power source to a DC energy that is stored by the traction battery.

5. The unitary on-board charger and generator of claim 3 further comprising:

a controller operable to:

engage the control switching element;

cycle the charging solid-state switching element, the mode switching element, and one or more of the plurality of switching elements to provide a predetermined charging voltage across the bridge capacitor; and

in response to the predetermined charging voltage being supplied to the bridge capacitor: disengage the charging solid-state switching element and the mode switching element, cycle one or more of the plurality of switching elements, and control the bi-directional DC/DC converter to convert a DC energy stored by the traction battery to a single-phase AC energy or a split-phase AC energy supplied to one or more output loads.

6. The unitary on-board charger and generator of claim 3 further comprising:

a controller operable to:

disengage the mode switching element, charging solid-state switching element, and the control switching element,

cycle one or more of the plurality of switching elements, and

control the bi-directional DC/DC converter to convert a DC energy stored by the traction battery to a three-phase AC energy that is supplied to one or more output loads.

7. The unitary on-board charger and generator of claim 2 , wherein the plurality of switching elements are IGBT transistors.

8. The unitary on-board charger and generator of claim 2 , wherein the plurality of switching elements are MOSFET transistors.

9. The unitary on-board charger and generator of claim 3 , wherein the charging solid-state switching element is a MOSFET transistor.

10. The unitary on-board charger and generator of claim 3 , wherein the charging solid-state switching element is an IGBT transistor.

11. The unitary on-board charger and generator of claim 1 , wherein the AC power source includes an electric vehicle supply equipment.

12. A unitary on-board charger and generator for an electric vehicle, comprising:

a charging circuit including:

a diode bridge rectifier connected to an AC power source,

a power factor correction converter connected between the diode bridge rectifier and a filtering capacitor, and

a bi-directional DC/DC converter connected between the filtering capacitor and a traction battery,

a generating circuit including:

an inverting circuit being connected to the filtering capacitor and the bi-directional DC/DC converter,

one or more inductive coils connected between the inverting circuit and one or more output capacitors; and

a bridge capacitor and a control switching element connected between the inverting circuit and filtering inductor at a first end and between the diode bridge rectifier and the power factor correction converter at a second end.

13. The unitary on-board charger and generator of claim 12 , wherein the power factor correction converter includes a charging inductor coil, a charging solid-state switching element, a charging diode, and a mode switching element parallelly connected to the charging diode.

14. The unitary on-board charger and generator of claim 13 , wherein the inverting circuit includes a first-phase output leg, a second-phase output leg, and a third-phase output leg.

15. The unitary on-board charger and generator of claim 14 , wherein the one or more inductive coils includes a first three-phase inductive coil connected to the first-phase output leg, a second three-phase inductive coil connected to the second-phase output leg, and a third three-phase inductive coil connected to the third-phase output leg.

16. The unitary on-board charger and generator of claim 15 , wherein the inverting circuit includes a plurality of switching elements.

17. The unitary on-board charger and generator of claim 16 further comprising:

a controller operable to:

disengage the mode switching element and the control switching element;

cycle the charging solid-state switching element at a predetermined frequency;

disengage one or more of the plurality of switching elements; and

control the bi-directional DC/DC converter to convert an AC energy received by the AC power source to a DC energy that is stored by the traction battery.

18. The unitary on-board charger and generator of claim 16 further comprising:

a controller operable to:

engage the control switching element;

cycle the charging solid-state switching element, the mode switching element, and one or more of the plurality of switching elements to provide a predetermined charging voltage across the bridge capacitor; and

in response to the predetermined charging voltage being supplied to the bridge capacitor: disengage the charging solid-state switching element and the mode switching element, cycle one or more of the plurality of switching elements, and control the bi-directional DC/DC converter to convert a DC energy stored by the traction battery to a single-phase AC energy or a split-phase AC energy supplied to one or more output loads.

19. The unitary on-board charger and generator of claim 16 further comprising:

a controller operable to:

disengage the mode switching element, charging solid-state switching element, and the control switching element,

cycle one or more of the plurality of switching elements, and

control the bi-directional DC/DC converter to convert a DC energy stored by the traction battery to a three-phase AC energy that is supplied to one or more output loads.

20. A method of charging a traction battery for an electric vehicle and powering an output load connected to the electric vehicle, comprising:

in response to detecting that an AC energy is being supplied by an AC power source to a diode bridge rectifier:

disengaging a mode switching element connected between the one or more inverting circuit switching elements and the diode bridge rectifier,

cycling a power factor correction converter at a predetermined frequency,

disengaging a control switching element, wherein the mode switching element is parallelly connected to a charging diode included within the power factor correction converter,

disengaging one or more inverting circuit switching elements, and

controlling a bi-directional DC/DC converter to convert the AC energy received by the AC power source to a DC energy that is stored by the traction battery,

in response to detecting the AC energy is not being supplied by the AC power source to the diode bridge and a single-phase load or a split-phase load being connected to the electric vehicle:

engaging the control switching element,

cycling the mode switching element, a charging solid-state switching element within the power factor correction converter, and the one or more inverting circuit switching elements to provide a predetermined charging voltage across a bridge capacitor, wherein the bridge capacitor is connected between the one or more inverting circuit switching elements and the diode bridge rectifier, and

disengaging the charging solid-state switching element and the mode switching element, and

controlling the bi-directional DC/DC converter to convert the DC energy stored by the traction battery to a single-phase AC energy or split-phase AC energy, and

in response to detecting the AC energy is not being supplied by the AC power source to the diode bridge and a three-phase load being connected to the electric vehicle:

disengaging the mode switching element, the charging solid-state switching element, and the control switching element,

cycling the one or more inverting circuit switching elements, and

controlling the bi-directional DC/DC converter to convert the DC energy stored by the traction battery to a three-phase AC energy.