Inductive power transfer system and method for operating an inductive power transfer system
09843199 · 2017-12-12
Assignee
Inventors
- Roman Bosshard (Aarau, CH)
- Johann Walter Kolar (Zurich, CH)
- Francisco Canales (Baden-Dattwil, CH)
- Beat Guggisberg (Untersiggenthal, CH)
- Guanghai Gong (Birmenstorf, CH)
- Bernhard Wunsch (Baden-Dattwil, CH)
Cpc classification
B60L5/005
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L53/122
PERFORMING OPERATIONS; TRANSPORTING
H02J50/80
ELECTRICITY
H02M1/0058
ELECTRICITY
B60L53/22
PERFORMING OPERATIONS; TRANSPORTING
Y02T90/14
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02J50/90
ELECTRICITY
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L53/126
PERFORMING OPERATIONS; TRANSPORTING
Y02T90/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02J7/00712
ELECTRICITY
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60L5/00
PERFORMING OPERATIONS; TRANSPORTING
H02J5/00
ELECTRICITY
H02J50/80
ELECTRICITY
Abstract
An exemplary inductive power transfer system having a transmitter coil and a receiver coil. A transmitter-side power converter having a mains rectifier stage powering a transmitter-side dc-bus and controlling a transmitter-side dc-bus voltage U.sub.1,dc. A transmitter-side inverter stage with a switching frequency f.sub.sw supplies the transmitter coil with an alternating current. A receiver-side power converter having a receiver-side rectifier stage that rectifies a voltage induced in the receiver coil and powering a receiver-side dc-bus and a receiver-side charging converter controlling a receiver-side dc-bus voltage U.sub.2,dc. Power controllers that determine from a power transfer efficiency of the power transfer, reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter and receiver side dc-bus voltages. An inverter stage switching controller controls the switching frequency f.sub.sw to reduce losses in the transmitter-side inverter stage.
Claims
1. An inductive power transfer system for supplying electrical power from a transmitter-side subsystem connectable to a mains to a receiver-side subsystem connectable to a load, the system comprising: a transmitter coil and a receiver coil; a transmitter-side power converter including a mains rectifier stage to power a transmitter-side dc-bus and arranged to control a transmitter-side dc-bus voltage U.sub.1,dc according to a corresponding reference value U.sub.1,dc*; a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current; a receiver-side power converter having a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc* ; one or more power controllers arranged to determine a value that is indicative of a power transfer efficiency of the power transfer and to calculate, from this value indicative of the power transfer efficiency, the reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc, an inverter stage switching controller arranged to control the turn-off time of the switches of the transmitter-side inverter stage to at least minimize switching losses in the transmitter-side inverter stage; and a communication channel for transmitting the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem to the transmitter-side subsystem.
2. The inductive power transfer system of claim 1, wherein the value that is indicative of the power transfer efficiency is a magnetic coupling k between the transmitter coil and receiver coil.
3. The inductive power transfer system of claim 1, wherein the value indicative of the power transfer efficiency is computed from a measurement of an input power P.sub.in input into the transmitter-side inverter stage or the transmitter coil and a measurement of a received power P.sub.out that is output by the receiver coil or the receiver-side rectifier stage.
4. The inductive power transfer system of claim 1, wherein at least one of the reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc is determined from a look-up table wherein reference values obtained from an off-line calculation are stored as a function of transmitter and receiver coil currents and a switching frequency f.sub.sw of the transmitter-side inverter stage.
5. The inductive power transfer system of claim 1, wherein the one or more power controllers are configured to compute the reference value U.sub.2,dc* for the receiver-side dc-bus voltage U.sub.2,dc from a measured difference between a load current I.sub.batt and a reference value I.sub.batt* for the load current; and to compute the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the reference value I.sub.batt* for the load current and a measured value of the load voltage U.sub.batt.
6. The inductive power transfer system of claim 1, wherein the value that is indicative of the power transfer efficiency is a magnetic coupling k between the transmitter coil and receiver coil.
7. The inductive power transfer system of claim 1, wherein the value indicative of the power transfer efficiency is computed from a measurement of an input power P.sub.in input into the transmitter-side inverter stage or the transmitter coil and a measurement of a received power P.sub.out that is output by the receiver coil or the receiver-side rectifier stage.
8. The inductive power transfer system of claim 1, wherein at least one of the reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc is determined from a look-up table wherein reference values obtained from an off-line calculation are stored as a function of transmitter and receiver coil currents and a switching frequency f.sub.sw of the transmitter-side inverter stage.
9. The inductive power transfer system of claim 1, wherein the one or more power controllers are configured to compute the reference value U.sub.2,dc* for the receiver-side dc-bus voltage U.sub.2,dc from a measured difference between a load current I.sub.batt and a reference value I.sub.batt* for the load current; and to compute the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the reference value I.sub.batt* for the load current and a measured value of the load voltage U.sub.batt.
10. The inductive power transfer system of claim 1, wherein the inverter stage switching controller is arranged to control the transmitter-side inverter stage in an inductive region close to the resonant frequency f.sub.0 of the transmitter for a switch-off current i.sub.1,off, corresponding to a value of the transmitter coil current i.sub.1(t) at the time of commutation, that is at a value that minimizes a switching loss of the transmitter-side inverter stage.
11. The inductive power transfer system of claim 1, wherein the inverter stage switching controller is arranged to control the turn-off time of the switches of the transmitter-side inverter stage for a switch-off current i.sub.1,off to follow a switch-off current reference value.
12. The inductive power transfer system of claim 1, wherein the inverter stage switching controller is arranged to estimate a power loss in the semiconductor switches of the transmitter-side inverter stage and to perform an iterative search procedure, varying the turn-off time of the switches of the transmitter-side inverter stage to minimize the power loss.
13. The inductive power transfer system of claim 1, wherein the inverter stage switching controller is arranged to control the turn-off time of the switches of the transmitter-side inverter stage for the transmitter coil current i.sub.1(t) to have a constant phase shift relative to the output voltage u.sub.1(t) of the transmitter-side inverter stage.
14. A transmitter side subsystem of an inductive power transfer system, connectable to a mains and being able to supply electrical power to a receiver-side subsystem, the transmitter side subsystem comprising: a transmitter coil; a transmitter-side power converter including a mains rectifier stage to power a transmitter-side dc-bus and arranged to control a transmitter-side dc-bus voltage U.sub.1,dc according to a corresponding reference value U.sub.1,dc*, and a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current; transmitter-side communication means for receiving the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem; and an inverter stage switching controller arranged to control the turn-off time of the switches of the transmitter-side inverter stage to at least minimize switching losses in the transmitter-side inverter stage transmitter-side inverter stag.
15. A receiver side subsystem of an inductive power transfer system, the receiver-side subsystem being connectable to a load and being able to receive electrical power from a transmitter-side subsystem, the receiver-side subsystem comprising: a receiver coil; a receiver-side power converter including a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc*; a receiver-side controller arranged to determine a value that is indicative of a power transfer efficiency of the power transfer and to calculate, from this value indicative of the power transfer efficiency, reference values U.sub.1,dc*, U.sub.2,dc* for a transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc, and receiver-side communication means for transmitting the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem to the transmitter-side subsystem.
16. A method for controlling an inductive power transfer system for supplying electrical power from a transmitter-side subsystem connectable to a mains to a receiver-side subsystem that is connectable to a load, the inductive power transfer system that includes: a transmitter coil and a receiver coil; a transmitter-side power converter having a mains rectifier stage to power a transmitter-side dc-bus; a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current; and a receiver-side power converter including a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc*; the method comprising the steps of: determining a value that is indicative of a power transfer efficiency of the power transfer and calculating, from this value indicative of the power transfer efficiency, reference values U.sub.1,dc*, U.sub.2,dc* for a transmitter-side dc-bus voltage U.sub.1,dc and a receiver-side dc-bus voltage U.sub.2,dc, transmitting the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem to the transmitter-side subsystem; controlling the mains rectifier stage for the transmitter-side dc-bus voltage U.sub.1,dc of the transmitter-side dc-bus to follow the corresponding reference value U.sub.1,dc*; controlling the receiver-side charging converter for the receiver-side dc-bus voltage U.sub.2,dc of the receiver-side dc-bus to follow the corresponding reference value U.sub.2,dc*; and controlling the turn-off time of the switches of the transmitter-side inverter stage to at least minimize switching losses in the transmitter-side inverter stage transmitter-side inverter stage.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the following, the disclosure is described with examples of exemplary embodiments, which are presented in the attached figures. They show schematically:
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(12) In all the figures, similar parts or parts with a similar function are labelled with the same reference numeral.
DETAILED DESCRIPTION
(13) Exemplary embodiments of the present disclosure provide a power transfer system, such as an inductive charging system, and a control method that lead to a high efficiency of the power transfer charging process in a wide range of operating conditions, output power and—for a charging system—state-of-charge dependent battery voltage. Exemplary embodiments of the present disclosure provides an inductive charging system that exhibits a large tolerance to coil misalignment and a high robustness with respect to component tolerances and parameter drifts.
(14) An exemplary embodiment of the present disclosure is directed to an inductive power transfer system, such as a battery charging system, for supplying electrical power from a transmitter-side subsystem connectable to a mains to a receiver-side subsystem connectable to a load. The system includes a transmitter coil and a receiver coil, a transmitter-side power converter having a mains rectifier stage to power a transmitter-side dc-bus and arranged to control a transmitter-side dc-bus voltage U.sub.1,dc according to a corresponding reference value U.sub.1,dc*, a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current (at a frequency equal to or close to a resonant frequency of the transmitter coil and receiver coil and any resonant compensations), a receiver-side power converter comprising a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc* (thereby controlling a charging current of the load), one or more power controllers arranged to determine a value that is indicative of a power transfer efficiency of the power transfer and to calculate, from this value indicative of the power transfer efficiency, the reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc, an inverter stage switching controller arranged to control the turn-off time of the switches of the transmitter-side inverter stage to at least approximately minimise switching losses in the transmitter-side inverter stage transmitter-side inverter stage.
(15) The power transfer efficiency can be the ratio between the electrical power fed into the transmitter coil and the electrical power drawn from the receiver coil. One or both of these power values can be replaced, respectively, by the power drawn from the transmitter-side dc-bus and entering the transmitter-side inverter stage or by the power drawn from the receiver-side rectifier stage and entering the receiver-side dc-bus. Also other power values that can be measured along the chain of converters between the mains and the battery can be used for controlling and optimizing the power transfer efficiency.
(16) The power controllers by controlling the two dc-bus voltages U.sub.1,dc, U.sub.2,dc (two control variables) allow control of the power transfer efficiency and the power flow into the load (two state variables). The power flow into the load can be directly linked to the load current. The reference values U.sub.1,dc*, U.sub.2,dc* can be computed to ensure that the power transfer efficiency is at a maximum.
(17) If the value indicative of the power transfer efficiency is correct, e.g., if the value corresponds to the actual power transfer efficiency, then controlling the two dc-bus voltages U.sub.1,dc, U.sub.2,dc to follow their reference values U.sub.1,dc*, U.sub.2,dc* will result in the maximum power transfer efficiency, in addition to a desired power flow into the load.
(18) If, however, the value indicative of the power transfer efficiency is not correct, then the reference values U.sub.1,dc*, U.sub.2,dc* for the two dc-bus voltages will not result in a satisfactory power transfer, and according to another exemplary embodiment an ideal power transfer, where the power flow into the load can still be controlled to follow the desired power flow. The exemplary inverter stage switching controller as described herein compensates for this discrepancy and can bring the power transfer back to an ideal condition.
(19) Thereby, the exemplary system of present disclosure reacts to changes in the resonant circuit due to a misalignment of the receiver coil with respect to the transmitter coil, due to component tolerances, or due to parameter drifts.
(20) In other words, the transmitter-side dc-bus voltage can be regulated with the mains rectifier stage and the receiver-side dc-bus voltage can be regulated with the receiver-side charging converter such that the battery current follows its reference value while at the same time the power loss in the transmission and the receiver coil is minimized. The control (pre-calculated off-line or derived in real-time) is such that the reactive power supplied by the transmitter-side power converter is always small and the efficiency of the power conversion is high, also during phases of reduced output power.
(21) Furthermore, the frequency of the alternating current in the transmitter coil can be regulated to compensate for changes in the resonant circuit due to coil misalignment, component tolerances, or parameter drifts. This has the advantage that the switching conditions of the power semiconductors of the transmitter-side inverter stage can be controlled such that the switching power loss is minimized.
(22) The control can be realized in a way that the only specified variable that should be transmitted via the communication channel is a reference value and not a measurement, which makes the system highly robust.
(23) In summary, an acceptable, or in another exemplary embodiment, ideal transmission can be achieved if the switching frequency is regulated to follow the resonant frequency of the IPT link and the two dc-link voltages U.sub.1,dc and U.sub.2,dc are used to control the output power.
(24) The transmitter and receiver can be distanced by an air gap. This can be the case if the disclosure is applied to an inductive charging system. The disclosure allows compensating for parameter changes in the coupling between the transmitter and receiver coils, and for other parameters as well.
(25) According to another exemplary embodiment, the transmitter and receiver can be part of a transformer. Stray inductances of the transformer are compensated by capacitances at the transmitter and/or receiver side, forming a resonant circuit. Exemplary embodiments of the present disclosure allow compensating for parameter changes due to ageing, temperature change, or other conditions as desired. The remaining explanations are in terms of an inductive charging system, but it is understood that they can be applied to other isolated DC-DC converters as well, and with other loads than batteries.
(26) If the coils of the power transfer system are part of an ordinary transformer, then the transmitter and receiver side subsystems, including the various controllers, can be part of the same physical device.
(27) If, however, the transmitter and receiver side subsystems are part of an inductive charging system, then these subsystems can be implemented as separate devices, and such a communication channel should be provided. This communication channel can be used to transmit the reference value U.sub.1,dc*, as mentioned above. Furthermore, for an ideal implementation information from the transmitter-side subsystem, such as the magnetic coupling k or the input power P.sub.in, is specified at the receiver-side subsystem. However, the latter information depends on parameters that change slowly—with time constants in the range of minutes-to-hours-to-days—and so any constraints on communication from the transmitter-side to the receiver-side subsystem are low.
(28) According to an exemplary embodiment of the present disclosure, the receiver side subsystem can include a receiver-side resonant compensation that with the receiver coil forms a resonant circuit having a resonant frequency. The system can also include, in addition to or instead of the receiver-side resonant compensation, a transmitter-side resonant compensation at the transmitter coil that reduces the reactive power demand of the resonant circuit at the resonant frequency.
(29) According to an exemplary embodiment described herein, the inductive power transfer system includes a communication channel for transmitting the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem to the transmitter-side subsystem.
(30) In an embodiment, the value that is indicative of the power transfer efficiency is a magnetic coupling (k) between the transmitter coil and receiver coil.
(31) According to another exemplary embodiment, the value that is indicative of the power transfer efficiency is computed from a measurement of an input power P.sub.in input into the transmitter-side inverter stage or the transmitter coil and a measurement of a received power P.sub.out that is output by the receiver coil or the receiver-side rectifier stage.
(32) According to still another exemplary embodiment, at least one of the reference values U.sub.1,dc*, U.sub.2,dc* for the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc is determined from a look-up table wherein reference values obtained from an off-line calculation are stored in function of transmitter and receiver coil currents and the switching frequency f.sub.sw of the transmitter-side inverter stage.
(33) According to an exemplary embodiment of the present disclosure, the one or more power controllers can be configured to compute the reference value U.sub.2,dc* for the receiver-side dc-bus voltage U.sub.2,dc from a measured difference between a load current I.sub.batt. and a reference value I.sub.batt* for the load current; and to compute the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the reference value I.sub.batt* for the load current and a measured value of the load voltage U.sub.batt.
(34) The functionality of the one or more power controllers can be implemented in a single controller or distributed over several controllers. For example, the receiver-side controller can determine both reference values U.sub.1,dc*, U.sub.2,dc* and transmit the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc to a transmitter-side controller. Alternatively, the receiver-side controller can compute an intermediate value and communicate it to the transmitter-side controller, which then computes the final reference value.
(35) According to yet another exemplary embodiment, the inverter stage switching controller is arranged to control the transmitter-side inverter stage in an inductive region close to the resonant frequency f.sub.0 of the transmitter for a switch-off current i.sub.1,off, corresponding to a value of the transmitter coil current i.sub.1(t) at the time of commutation, that is at a value that minimizes a switching loss of the transmitter-side inverter stage.
(36) According to another exemplary embodiment, the inverter stage switching controller is arranged to control the turn-off time of the switches of the transmitter-side inverter stage for a switch-off current i.sub.1,off to follow a switch-off current reference value.
(37) The acceptable, or according to another exemplary embodiment, ideal value of the switched current i.sub.1,off that minimizes the switching loss of the power semiconductor can be estimated in real-time from a mathematical model of the power semiconductor, or from a look up table, given a measurement of the transmitter coil current i.sub.1(t), the switching frequency f.sub.sw, and the transmitter-side dc-bus voltage U.sub.1,dc.
(38) According to an exemplary embodiment of the present disclosure, the inverter stage switching controller can be arranged to estimate a power loss in the semiconductor switches of the transmitter-side inverter stage and to perform an iterative search procedure, varying the turn-off time of the switches, to minimize the power loss.
(39) In an exemplary embodiment, the inverter stage switching controller can be arranged to control the turn-off time of the switches of the transmitter-side inverter stage for the transmitter coil current i.sub.1(t) to have a constant phase shift relative to the output voltage u.sub.1(t) of the transmitter-side inverter stage
(40) An exemplary transmitter side subsystem of an inductive power transfer system of the present disclosure can be connectable to a mains and being able to supply electrical power to a receiver-side subsystem, includes a transmitter coil, a transmitter-side power converter having a mains rectifier stage to power a transmitter-side dc-bus and arranged to control a transmitter-side dc-bus voltage U.sub.1,dc according to a corresponding reference value U.sub.1,dc*, and a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current, transmitter-side communication (e.g., a transmitter, receiver, or transceiver) means for receiving the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem, an inverter stage switching controller arranged to control the turn-off time of the switches of the transmitter-side inverter stage to at least approximately minimize switching losses in the transmitter-side inverter stage transmitter-side inverter stage.
(41) An exemplary receiver side subsystem of an inductive power transfer system of the present disclosure can be connectable to a load and being able to receive electrical power from a transmitter-side subsystem, includes a receiver coil, a receiver-side power converter having a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc*, a receiver-side controller arranged to determine a value that is indicative of a power transfer efficiency of the power transfer and to calculate, from this value indicative of the power transfer efficiency, reference values U.sub.1,dc*, U.sub.2,dc* for a transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc, and a receiver-side communication means for transmitting the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side subsystem to the transmitter-side subsystem.
(42) The exemplary method serves for controlling an inductive power transfer system, such as a battery charging system, for supplying electrical power from a transmitter-side subsystem connectable to a mains to a receiver-side subsystem connectable to a load, the inductive power transfer system including a transmitter coil and a receiver coil, a transmitter-side power converter including a mains rectifier stage to power a transmitter-side dc-bus, a transmitter-side inverter stage with a controllable turn-off time of switches of the transmitter-side inverter stage to supply the transmitter coil with an alternating current and a receiver-side power converter having a receiver-side rectifier stage to rectify a voltage induced in the receiver coil and to power a receiver-side dc-bus and a receiver-side charging converter arranged to control a receiver-side dc-bus voltage U.sub.2,dc according to a corresponding reference value U.sub.2,dc*.
(43) According to an exemplary embodiment of the present disclosure, the method includes the steps of determining a value that is indicative of a power transfer efficiency of the power transfer and calculating, from this value indicative of the power transfer efficiency, reference values U.sub.1,dc*, U.sub.2,dc* for a transmitter-side dc-bus voltage U.sub.1,dc and a receiver-side dc-bus voltage U.sub.2,dc; controlling the mains rectifier stage for the transmitter-side dc-bus voltage U.sub.1,dc of the transmitter-side dc-bus to follow the corresponding reference value U.sub.1,dc*; controlling the receiver-side charging converter for the receiver-side dc-bus voltage U.sub.2,dc of the receiver-side dc-bus to follow the corresponding reference value U.sub.2,dc*; controlling the turn-off time of the switches of the transmitter-side inverter stage to at least approximately minimize switching losses in the transmitter-side inverter stage transmitter-side inverter stage.
(44) According to exemplary embodiments described herein, the turn-off time of the switches of the transmitter-side inverter stage can be controlled by controlling the switching frequency f.sub.sw of the transmitter-side inverter stage, by controlling the duty-cycle of the voltages applied by the transmitter-side inverter stage, or by a combination of both.
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(46) According to an exemplary embodiment of the present disclosure, the at least one resonant capacitor of the receiver-side resonant compensation 6 is connected to the receiver coil 4 in parallel, while the functionality of the disclosure remains unchanged. Together with the transmitter coil 3 and the receiver coil 4, the transmitter-side resonant compensation 5 and the receiver-side resonant compensation 6 form a resonant circuit 7 with a resonant frequency f.sub.0 at which an input impedance of the resonant circuit 7 is ohmic. Connected to the transmitter-side resonant compensation 5 is a transmitter-side power converter 8. The transmitter-side power converter 8 includes a transmitter-side inverter stage 9, a transmitter-side dc-bus 10 with a transmitter-side dc-bus voltage U.sub.1,dc and a mains rectifier stage 11 connected to the transmitter-side dc-bus 10 and the mains 1.
(47) According to the exemplary embodiment shown in
(48) Connected to the receiver-side resonant compensation 6 is a receiver-side power converter 12. The receiver-side power converter 12 includes a receiver-side rectifier stage 13, a receiver-side dc-bus 14 with a receiver-side dc-bus voltage U.sub.2,dc, a receiver-side charging converter 15, and an output filter 16. Connected to the receiver-side power converter 12 at the output filter 16 is the battery 2. An inductive part of the output filter 16 can be realized either by an explicit or discrete inductor or alternatively by an inductance of a connection cable between the receiver-side charging converter 15 and the battery 2. According to an exemplary embodiment, additional filter elements to reduce a stray field can be connected between the transmitter-side power converter 8 and the transmitter-side resonant compensation 5 or between the receiver-side power converter 9 and the receiver side resonant compensation 6. A battery voltage U.sub.batt and a battery current I.sub.batt are measured on the receiver-side power converter 12. A battery power P.sub.batt that is, the power flowing into the battery, can be calculated from the battery voltage U.sub.batt and the battery current I.sub.batt. A communication channel 17 can provide communication between a transmitter-side controller 18 and a receiver-side controller 19. The communication channel can be a wireless communication channel, while other realizations are also possible.
(49) The transmitter-side inverter stage 9 of the transmitter-side power converter 8 is switched by an inverter stage or transmission side switching controller 20 at a switching frequency f.sub.sw close to or at the resonant frequency f.sub.0 of the resonant circuit 7.
(50) The transmitter coil current measurement 21 can include an electrical circuit to detect the zero-crossings of the transmitter coil current i.sub.1(t), which can be used to trigger an integrator or counter of the transmitter-side controller 20. The integrator is reset at each zero-crossing. From the integrator value before the reset, which is proportional to the elapsed time between zero-crossings, an oscillation frequency of the transmitter coil current i.sub.1(t) can be determined from which the resonant frequency f.sub.0 can be estimated. The switching frequency f.sub.sw is regulated by the inverter stage switching controller 20 in an inductive region close to the resonant frequency f.sub.0 such that a switched current i.sub.1,off, which corresponds to a value of the transmitter coil current i.sub.1(t) at the time of a commutation as shown in
(51) The acceptable, or according to another exemplary embodiment, ideal value of the switched current i.sub.1,off that minimizes the switching loss of the transmitter-side inverter stage 9 can be estimated in real-time with a mathematical model of the power semiconductor based on the transmitter coil current measurement 21, the switching frequency f.sub.sw, and the transmitter-side dc-bus voltage U.sub.1,dc.
(52) According to another exemplary embodiment of the present disclosure, the acceptable, or according to another exemplary embodiment, ideal value of the switched current i.sub.1,off can be determined in real-time by a power loss estimation and an iterative search method. The estimation can be based on the temperature of the switches or on measurements of voltages and currents at the switches or from a difference of the power delivered by the transmitter-side dc-bus 10 and the power absorbed by the transmitter coil 3.
(53) According to yet another exemplary embodiment, a current look-up table can be used, where the acceptable, or according to another exemplary embodiment, ideal value of the switched current i.sub.1,off is pre-calculated and stored, in function of the transmitter coil current i.sub.1(t), the switching frequency f.sub.sw, and the transmitter-side dc-bus voltage U.sub.1,dc.
(54) Still, according to another exemplary embodiment of the present disclosure, an acceptable, or according to another exemplary embodiment, ideal phase angle between i.sub.1(t) and u.sub.1(t) can be pre-calculated and used to control the switching frequency that leads to this phase angle. The acceptable or ideal phase angle is not dependent on operating conditions of the inverter stage.
(55) In addition to or instead of adapting the switching frequency f.sub.sw, a duty cycle time for the output voltage u.sub.1(t) of the transmitter-side inverter stage 9 can be adapted in order to set the switch-off time and the switch-off current.
(56) A mains rectifier switching controller 22 of the mains rectifier stage 11 is used by the transmitter-side controller 18 to regulate the transmitter-side dc-bus voltage U.sub.1,dc by space-vector or phase-oriented control techniques according to known implementations. To perform this regulation, the transmitter-side controller 18 uses the communication channel 17 to receive information about a reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc from the receiver-side controller 19.
(57) The battery current I.sub.batt is controlled by the receiver-side controller 19 using a charging converter switching controller 23 of the receiver-side charging converter 15 according to a reference value I.sub.batt*, which can be obtained from a charging profile similar to the one shown in
(58) It can be shown that for a series-series compensated inductive power transfer system between the transmitter-side dc-bus 10 and the receiver-side dc-bus 14 the maximum transmission efficiency at the angular resonant frequency ω.sub.0=2πf.sub.0 is achieved by choosing the reactance of the receiver coil to be
(59)
and the transmitter coil self-inductance to be
(60)
where k.sub.0 denotes the magnetic coupling at the nominal position of the coils. This design ensures an acceptable, or according to another exemplary embodiment, ideal matching of the receiver coil to the equivalent resistance of the load at the nominal point, which is given by
(61)
for a diode rectifier with a capacitive output filter. The resonant frequency is set by choosing the capacitances for the transmitter and the receiver side resonant compensation as
(62)
(63) It furthermore can be shown that for a series-series compensated inductive power transfer system the output power P.sub.2 is
(64)
and therefore, if the dc-link voltages are controlled, the battery current can be regulated according to
(65)
because the battery is a voltage-impressing element and the battery current results from I.sub.batt=P.sub.2/U.sub.batt.
(66) The condition for the maximum efficiency of the IPT system is that the receiver reactance is matched to the equivalent load resistance (3) according to (1). Hence, if the receiver-side dc-link voltage can be controlled according to
(67)
(given the actual magnetic coupling k), at reduced output power, the equivalent load resistance is maintained constant and the matching condition is fulfilled. Because of the symmetry of (4), it is sufficient if a feedback controller is used to adapt one of the reference values of the dc-link voltages dynamically to compensate for inaccuracies in the model and the calculations. The reference value for the primary dc-link voltage follows from (2) as
(68)
(69) In summary, the battery power P.sub.batt is a function of a product of the transmitter-side dc-bus voltage U.sub.1,dc and the receiver-side dc-bus voltage U.sub.2,dc, hence, the battery power can be controlled by adapting either of the dc-bus voltages. Therefore, three different control methods are possible:
(70)
(71) According to another exemplary embodiment, as shown in
(72) According to yet another exemplary embodiment, as shown in
(73)
(74) In the control methods in which the transmitter-side dc-bus voltage U.sub.1,dc is adapted with the PI-controller instead of the receiver-side dc-bus voltage U.sub.2,dc the reaction time of the battery current control loop will likely be lower, due to the delay that is introduced by the communication across the air gap. Therefore, according to an exemplary embodiment of the present disclosure, this control loop and critical parts (overheating, overcurrent and overvoltage protection) of the battery charging control are implemented on the receiver, which has a more direct access to the measurements.
(75) To calculate the reference values (6) and (7) accurately, an estimate of the magnetic coupling k should be generated. If a feedback controller is used, also a pre-calculated, approximate value can be used and the controller will compensate for the estimation error. Additionally or alternatively, the magnetic coupling can be estimated in real time, for example, from measurements of the currents in the coils and an equivalent circuit.
(76) According to another exemplary embodiment, the reference value U.sub.1,dc* and the reference value U.sub.2,dc* can be determined from a voltage look-up table where the reference values obtained from an off-line calculation are stored in function of the transmitter and receiver coil currents and the switching frequency f.sub.sw of the transmitter-side inverter stage.
(77) The minimum communication for the acceptable, or according to another exemplary embodiment, ideal control is the transmission of the reference value U.sub.1,dc* for the transmitter-side dc-bus voltage U.sub.1,dc, which makes the system highly robust to a failure of the communication channel 17. If communication is lost, U.sub.1,dc remains constant, then this will be compensated for by the voltage controller on the receiver side.
(78)
(79) According to the exemplary methods of the present disclosure, the transmitter-side dc-bus voltage U.sub.1,dc, the receiver-side dc-bus voltage U.sub.2,dc, and/or the switching frequency f.sub.sw are regulated to compensate for changes in the resonant circuit 7 due to a misalignment of the receiver coil 4 with respect to the transmitter coil 3, due to component tolerances, or due to parameter drifts.
(80) As shown in
(81) In another exemplary embodiment having the same electrical circuit and functionality as either of the previously described embodiments, an on-time t.sub.on as shown in
(82) Further structural variants of the system are now described which can use the same control methods as described above.
(83) Another exemplary embodiment of the present disclosure is shown in
(84) In yet another exemplary embodiment of the present disclosure, the mains rectifier stage 11 of the embodiment shown in
(85) In yet another exemplary embodiment of the present disclosure, the mains rectifier stage 11 of the embodiment shown in
(86) In another exemplary embodiment of the present disclosure, the transmitter-side inverter stage 9 and the mains rectifier stage 11 of
(87) In yet another exemplary embodiment, the receiver-side rectifier stage 13 and receiver-side charging converter 15 are integrated, optionally in addition to an integration of the transmitter-side power converter 8, while the remainder of the electrical circuit and the functionality remains the same as that of the embodiment shown in
(88) According to exemplary embodiments of the present disclosure the various types of controllers described in the context of the present disclosure can include one or more of any known general purpose processor or integrated circuit such as a central processing unit (CPU), microprocessor, field programmable gate array (FPGA), Application Specific Integrated Circuit (ASIC), or other suitable programmable processing or computing device or circuit as desired. The general processor(s) can be configured to include and perform features of the exemplary embodiments of the present disclosure, such as, those features specified for realizing a method for supplying electrical power from a transmitter-side subsystem connectable to a mains to a receiver-side subsystem connectable to a load, and thereby the processor(s) functions as a special and unique processor. The features can be performed through program code encoded or recorded on the processor(s), or stored in a non-volatile memory device, such as Read-Only Memory (ROM), erasable programmable read-only memory (EPROM), or other suitable memory device or circuit as desired. In another exemplary embodiment, the program code can be provided in a computer program product having a non-transitory computer readable medium, such as Magnetic Storage Media (e.g. hard disks, floppy discs, or magnetic tape), optical media (e.g., any type of compact disc (CD), or any type of digital video disc (DVD), or other compatible non-volatile memory device as desired) and downloaded to the processor(s) for execution as desired, when the non-transitory computer readable medium is placed in communicable contact with the processor(s).
(89) Thus, it will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.