Pick-up apparatus for inductive power transfer systems

Abstract

An Inductive Power Transfer (IPT) pick-up apparatus includes a magnetically permeable core, a first coil, being wound about the core so as to be inductive coupled therewith such that a current induced in the first coil is most sensitive to a first directional component of magnetic flux and a second coil, being wound about the core so as to be inductively coupled therewith such that a current induced in the second coil is most sensitive to a second directional component of magnetic flux. The first directional component is substantially orthogonal to the second directional component.

Claims

.[.1. An Inductive Power Transfer (IPT) pick-up apparatus comprising: a magnetically permeable core; a first coil, being wound about the core so as to be inductive coupled therewith such that a current induced in the first coil is most sensitive to a first directional component of magnetic flux; and a second coil, being wound about the core so as to be inductively coupled therewith such that a current induced in the second coil is most sensitive to a second directional component of magnetic flux; wherein the first directional component is substantially orthogonal to the second directional component..].

.[.2. An IPT pick-up apparatus as claimed in claim 1, wherein the first directional component is a vertical component of magnetic flux and the second directional component is a horizontal component of magnetic flux..].

.[.3. An IPT pick-up apparatus as claimed in claim 1, wherein the first and second coils are wound orthogonally to each other such that the current induced in one coil is most sensitive to the first directional component of magnetic flux, and the current induced in the other coil is most sensitive to the second directional component of magnetic flux..].

.[.4. An IPT pick-up apparatus as claimed in claim 1, wherein the first coil comprises a first pair of half-coils, and the second coil comprises a second pair of half-coils..].

.[.5. An IPT pick-up apparatus as claimed in claim 1, wherein the core is constructed with a flat E cross-section..].

.[.6. An IPT pick-up apparatus as claimed in claim 1, wherein the core is constructed from a permeable ferrous material such as ferrite..].

.[.7. An IPT pick-up apparatus as claimed in claim 1, wherein each coil is independently tuned with one or more capacitors..].

.[.8. An IPT pick-up apparatus as claimed in claim 1, wherein the apparatus comprises an electrical circuit to independently rectify the current induced in each coil..].

.[.9. An IPT pick-up apparatus as claimed in claim 1, wherein the apparatus comprises an electrical circuit to sum and regulate the rectified output from the coils such that the total output power is essentially constant over a wide range of lateral movement of the apparatus relative to the source of magnetic flux..].

.[.10. An Inductive Power Transfer (IPT) pick-up apparatus comprising: a magnetically permeable E-shaped core having at least three substantially parallel legs and connection regions connecting adjacent legs to each other, the connection regions having an axis which is orthogonal to the axes of the legs; a first set of part-coils and a second set of part-coils each wound about the core so as to be inductively coupled therewith, the first set being arranged such that the current induced therein is most sensitive to a directional component of magnetic flux substantially parallel to the axes of the legs, and the second set being arranged to be sensitive to a directional component of magnetic flux substantially parallel to the axis of the connection portions..].

.[.11. An IPT pick-up apparatus as claimed in claim 10, wherein at least one of the part-coils of the first set and at least one of the part-coils of the second set is provided on one of the connection regions and at least one of the part-coils of each set is provided on one or more other connection regions..].

.[.12. An IPT pick-up apparatus as claimed in claim 10, wherein one or more separate tuning capacitors are provided for each coil set..].

.[.13. An Inductive Power Transfer (IPT) pick-up apparatus comprising: a magnetically permeable core; a first coil, being wound about the core so as to be inductive coupled therewith such that a current induced in the first coil is most sensitive to a first directional component of magnetic flux; a second coil, being wound about the core so as to be inductively coupled therewith such that a current induced in the second coil is most sensitive to a second directional component of magnetic flux; and a track having one or more primary conductors, the one or more primary conductors being capable of providing the magnetic flux; wherein the first directional component is substantially orthogonal to the second directional component..].

.[.14. An Inductive Power Transfer (IPT) pick-up apparatus comprising: a magnetically permeable E-shaped core having at least three substantially parallel legs and connection regions connecting adjacent legs to each other, the connection regions having an axis which is orthogonal to the axes of the legs; a first set of part-coils and a second set of part-coils each wound about the core so as to be inductively coupled therewith, the first set being arranged such that the current induced therein is most sensitive to a directional component of magnetic flux substantially parallel to the axes of the legs, and the second set being arranged to be sensitive to a directional component of magnetic flux substantially parallel to the axis of the connection portions; and a track having one or more primary conductors, the one or more primary conductors being capable of providing the magnetic flux..].

.Iadd.15. An inductive power transfer apparatus comprising: a tuned multiple coil inductive power pick-up, the pick-up including a first tuned coil and a second tuned coil, wherein: a current induced in the first tuned coil being most sensitive to a first directional component of magnetic flux generated by a first track segment configured to generate a corresponding anticlockwise magnetic field in response to current flowing in a first direction through the first track; and a current induced in the second tuned coil being most sensitive to a second directional component of magnetic flux generated by a second track segment configured to generate a corresponding clockwise magnetic field in response to current flowing in a second direction through the second track segment, the second direction opposite from the first direction; and an electrical circuit configured to sum and regulate the currents induced in the first and second tuned coils to provide a substantially constant total power output over a range of lateral movement of the pick-up without requiring a battery, the range including at least a first pick-up position over the first track to a third pick-up position over a third track; wherein: the third track segment is configured to generate a corresponding anticlockwise magnetic field in response to current flowing in the first direction through the third track; the first, second, and third segments are arranged substantially in a common plane such that the generated magnetic field exits between the first and second track segments and enters between the second and third track segments; and the generated magnetic field further includes the first and second directional components of magnetic flux..Iaddend.

.Iadd.16. The inductive power transfer apparatus of claim 15, further comprising a fourth track segment configured to generate a corresponding clockwise magnetic field in response to current flowing through the fourth track segment, the fourth track segment arranged substantially in a common plane with the first, second and third track segments such that the generated magnetic field further exits between the third and fourth track segments..Iaddend.

.Iadd.17. The inductive power transfer apparatus of claim 15, wherein the second track segment is arranged between the first track segment and the third track segment..Iaddend.

.Iadd.18. The apparatus of claim 15, wherein the first, second and third track segments are configured as a single phase track system..Iaddend.

.Iadd.19. The apparatus of claim 15, wherein the first, second and third track circuit are configured as a multi-phase track system..Iaddend.

.Iadd.20. The apparatus of claim 15, wherein the horizontal pick-up position range includes a lateral pick-up movement of at least 50 mm, the lateral pick-up movement being perpendicular to the first, second, and third track segments..Iaddend.

.Iadd.21. The apparatus of claim 15, wherein the first and second tuned coils are each independently connected to one or more tuned capacitors..Iaddend.

.Iadd.22. The apparatus of claim 15, further comprising an electrical circuit configured to independently rectify the current induced in each of the first and second tuned coils..Iaddend.

.Iadd.23. An inductive power transfer apparatus comprising: a first track segment configured to generate a corresponding anticlockwise magnetic field in response to current flowing in a first direction through the first track; a second track segment configured to generate a corresponding clockwise magnetic field in response to current flowing in a second direction through the second track segment, the second direction opposite from the first direction; a third track segment configured to generate a corresponding anticlockwise magnetic field in response to current flowing in the first direction through the third track, the first, second, and third segments arranged substantially in a common plane such that the generated magnetic field exits between the first and second track segments and enters between the second and third track segments, the generated magnetic field further including first and second directional components of magnetic flux; and a tuned multiple coil inductive power pick-up, the pick-up including a first tuned coil and a second tuned coil, a current induced in the first tuned coil being most sensitive to the first directional component of magnetic flux, and a current induced in the second tuned coil being most sensitive to the second directional component of magnetic flux, and an electrical circuit configured to sum and regulate the currents induced in the first and second tuned coils to provide a substantially constant total power output over a range of lateral movement of the pick-up without requiring a battery, the range including at least a first pick-up position over the first track to a third pick-up position over the third track..Iaddend.

Description

DRAWING DESCRIPTION

(1) A number of embodiments of the invention will now be described with reference to the drawings in which:

(2) FIG. 1 is a diagrammatic cross-section of an IPT pick-up according to one embodiment of the invention.

(3) FIG. 2 is one possible tuning and power control circuit for the pick-up structure of FIG. 1.

(4) FIG. 3 is the power profile for the pick-up structure of FIG. 1.

(5) FIG. 4 is the same pick-up as that shown in FIG. 1, but positioned above two pairs of single phase tracks.

(6) FIG. 5 is the power profile for the pick-up structure of FIG. 4.

(7) FIG. 6 is a cross-section of a second embodiment of the invention.

(8) FIG. 7 is one possible tuning and power control circuit for the pick-up structure of FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

(9) Throughout the description like reference numerals will be used to refer to like features in different embodiments.

(10) Referring first to FIG. 1, a pick-up geometry according to a first embodiment of the invention is shown by way of example, arranged to capture flux having a first directional component, being substantially vertical, and a second directional component, being substantially horizontal.

(11) Those skilled in the art will appreciate that the directional components of magnetic flux will vary dependent on the orientation of the system. For ease of description, the terms vertical and horizontal are used to describe direction in relation to examples in which the primary conductors providing the magnetic flux are laid on or in a floor, and the pick-up is designed to travel over the floor, intercepting magnetic flux generated by the conductors which are energized in the known way.

(12) The apparatus in this embodiment comprises a core 1 having an E-shaped cross-section (preferably constructed of magnetically-permeable ferrite or a material having similar desirable magnetic properties), with three substantially parallel vertical legs and orthogonal connection regions connecting adjacent legs to each other. A core of this geometry may be referred to as a Flat E Core.

(13) The core 1 is provided with a first coil 2 wound around a vertical axis and a second coil 3 wound around a horizontal axis of the core. The pick-up is shown positioned so that the coil is situated between the two track conductors 4 and 5 with current flowing in opposing directions, producing anticlockwise and clockwise magnetic fields, respectively. In this configuration, the current induced in the coil 2 is maximum when the coil is positioned between the two track conductors 4 and 5 (as illustrated), and drops to zero as the coil is moved directly above either of the two conductors. Conversely, the current induced in the coil 3 is maximum when the coil is positioned directly above either of the track conductors 4 or 5, and drops to zero as the coil approaches the midpoint between the two conductors. Therefore, coil 2 is most sensitive to magnetic flux in one direction (a vertical direction as shown in FIG. 1), and coil 3 is most sensitive to magnetic flux in another direction (a horizontal direction as shown in FIG. 1). Accordingly this arrangement, in which the coils are substantially orthogonal to each other, allows a pick-up to extract power over a wider range of movement relative to the track conductors, meaning it has greater tolerance to misalignment. In particular, the pick-up can extract power from the track conductors over a wider horizontal distance.

(14) FIG. 2 shows a possible tuning and power control circuit for the pick-up configuration of FIG. 1, including independent tuning capacitors (6 and 7) and rectifiers (8 and 9) for the coils 2 and 3, respectively, and a regulating circuit generally referenced 10 which operates in the known way, decoupling the pick-up from the primary conductors to supply a constant voltage to the load 11. This control strategy is described in greater detail in U.S. Pat. No. 5,293,308, the contents of which are incorporated herein by reference.

(15) Series tuning capacitors may also be provided if required for each coil to ensure that the effective short circuit current and open circuit voltage outputs of both the first and second coils can be matched, thereby ensuring a power profile that is as even as possible across the width of a track.

(16) FIG. 3 shows a typical uncompensated power profile for the circuit of FIG. 2, if used in a single phase track circuit with two wires corresponding to the arrangement shown in FIG. 1 where dx=0 mm is the centre of the track, and conductors 4 and 5 are located at dx=50 mm and +50 mm. This figure illustrates the complimentary power profiles of the coils 2 and 3. Locus 16 shows the power profile for the vertical coil 2 and locus 17 shows the power profile for the horizontal coil 3. The total power available when tuned will be the operating quality factor of the combined circuit (Q) multiplied by the combined uncompensated power which is shown by locus 18. This shows the capability of the pick-up to extract power over a wide horizontal tolerance range (greater than 3 times that of a single pick-up with only vertical or horizontal flux capture). This circuit has been found to be remarkably effective.

(17) Typically, track conductors for floor mounted AGVs are 100 mm apart and a misalignment of the order of 25 mm will reduce the power to a level so low as to be impractical using existing circuits. However, with a pick-up such as that shown in FIG. 1, a misalignment of more than 100 mm to either side still gives an acceptable power output. In roadway applications where the surface is likely to be uneven this tolerance is of great value and makes driver-operated vehicles a practical proposition.

(18) The number of conducting tracks may be increased to allow a wider range of motion of the pick-up, for example the use of two track circuits is shown in FIG. 4. By adding more track circuits the tolerance to horizontal misalignment can be as great as required for any situation. It will be seen that in the embodiments illustrated all of these track circuits operate in a single phase mode. It will be appreciated by those skilled in the art, however, that the apparatus may also be used with a multiple-phase track system.

(19) The associated power profile for the two pairs of single phase tracks of FIG. 4 is shown in FIG. 5 in which locus 19 shows the power profile for the vertical coil 2 and locus 20 shows the power profile for the horizontal coil 3. The total power profile is shown by locus 21. Again, dx=0 mm is the centre of the track, and conductors 4 and 5 are located at dx=100 mm, 50 mm, +50 mm and +100 mm.

(20) FIG. 6 shows a second embodiment of the pick-up apparatus according to the invention, in which the two coils each comprise a set of part-coils (in this embodiment half-coils), 12 and 13, and 14 and 15. In this configuration, the vertical component of magnetic flux flows through the central leg of the E core and splits through the connection portions of the core which are provided either side of the central leg and connect the central leg to the remaining two legs of the core. As can be seen axes of the connecting portions are orthogonal to axes of the legs. As the part-coils are provided on the connection portions, coils 14 and 15 which are most sensitive to the vertical flux component need to be arranged as shown in FIG. 7 to sum the induced current which will be in a different direction in each coil. Coils 12 and 13 are most sensitive to the horizontal flux component and are arranged to sum the induced currents. The associated tuning and power control circuit for this embodiment is shown in FIG. 7.

(21) The tuning capacitors in FIG. 7 must all be individually chosen as they all correspond to different magnetic circuits. Again this wiring arrangement gives the same form of output as indicated in FIG. 5 and can be extended indefinitely by adding extra track circuits. Also, the E core may be extended by adding additional legs and connection portions, with further part-coils. Again, series tuning capacitors can be provided for the coil sets to match the outputs of the coil sets, and thus provide a power profile that is as even as possible across the width of the track.

(22) From the foregoing it will be seen that the pick-up apparatus increases the useful range of lateral movement while still achieving useful power outputs with little change or added cost to the electronic control circuitry. In at least one practical-IPT application, these circuits are particularly useful with simple single circuit tracks and typically increase the useful range of lateral movement from 50 mm to 150 mm while still achieving useful power outputs.

(23) Unless the context clearly requires otherwise, throughout the description the words comprise, comprising, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of including, but not limited to.

(24) Where in the foregoing description reference has been made to specific components or integers of the invention having known equivalents, then such equivalents are herein incorporated as if individually set forth.

(25) Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the scope of the invention.