US20150236513A1 - Multiple coil flux pad - Google Patents

Multiple coil flux pad Download PDF

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Publication number
US20150236513A1
US20150236513A1 US14/379,068 US201314379068A US2015236513A1 US 20150236513 A1 US20150236513 A1 US 20150236513A1 US 201314379068 A US201314379068 A US 201314379068A US 2015236513 A1 US2015236513 A1 US 2015236513A1
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United States
Prior art keywords
coils
pad
magnetic flux
power supply
coil
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Abandoned
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US14/379,068
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English (en)
Inventor
Grant Anthony Covic
John Talbot Boys
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Auckland Uniservices Ltd
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Auckland Uniservices Ltd
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Assigned to AUCKLAND UNISERVICES LIMITED reassignment AUCKLAND UNISERVICES LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOYS, JOHN TALBOT, COVIC, GRANT ANTHONY
Publication of US20150236513A1 publication Critical patent/US20150236513A1/en
Assigned to QUALCOMM INCORPORATED reassignment QUALCOMM INCORPORATED LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: AUCKLAND UNISERVICES LIMITED
Assigned to WITRICITY CORPORATION reassignment WITRICITY CORPORATION LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: QUALCOMM INCORPORATED
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/40—Circuit arrangements or systems for wireless supply or distribution of electric power using two or more transmitting or receiving devices
    • H02J7/025—
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/288—Shielding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2871—Pancake coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/14—Inductive couplings
    • H02J5/005—
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/005—Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H02J50/12—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling of the resonant type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/70—Circuit arrangements or systems for wireless supply or distribution of electric power involving the reduction of electric, magnetic or electromagnetic leakage fields
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/90—Circuit arrangements or systems for wireless supply or distribution of electric power involving detection or optimisation of position, e.g. alignment
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2310/00—The network for supplying or distributing electric power characterised by its spatial reach or by the load
    • H02J2310/40—The network being an on-board power network, i.e. within a vehicle
    • H02J2310/48—The network being an on-board power network, i.e. within a vehicle for electric vehicles [EV] or hybrid vehicles [HEV]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0042—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction
    • H02J7/0044—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction specially adapted for holding portable devices containing batteries
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/12—Electric charging stations
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Definitions

  • This invention relates to apparatus for generating or receiving magnetic flux.
  • the invention has particular, but not sole, application to a low profile, substantially flat device such as a pad for power transfer using an inductive power transfer (IPT) system.
  • IPT inductive power transfer
  • IPT power transfer pads are electric vehicle charging, and that application is discussed in this section to provide the background to one application of the invention.
  • electric vehicle charging is an example of only one application, and the invention has application to inductive power transfer in general.
  • Electric vehicle charging may occur while the vehicle is stationary, or alternatively while the vehicle is moving along a roadway, for example.
  • IPT power transfer pads can be used both in the vehicle as a power “pickup” (i.e. the secondary side winding of the IPT system), and at a stationary location such as a garage floor or a roadway for example as the “charging pad” (i.e. the primary side winding) from which power is sourced.
  • the purpose of an IPT roadway system is to wirelessly transfer power to a stationary or moving vehicle without physical contact to the vehicle.
  • the transmitting part of the system consists of a power supply supplying a lumped coil (for example a pad as described above) or a track with many similar lumped coils where such a system is tuned for operation at a suitable frequency, usually anywhere from 10 kHz to 150 kHz.
  • a suitable frequency usually anywhere from 10 kHz to 150 kHz.
  • the pickup receiver also typically comprises a lumped coil (such as a pad described above) which is connected to a converter and appropriate controller within the vehicle to regulate power.
  • a track For convenience, the part of a roadway from which power may be received inductively is referred to herein as a track.
  • the track may be formed by placing a plurality of pads along the centre of a lane in a roadway.
  • the power transfer profile in the pick-up pad is ideally a smooth power profile which is essentially constant (and sufficient) over as wide as possible a distance laterally, with smooth drop-offs at each end.
  • Such a power transfer profile eases the demands on the electronic (primary and secondary) regulators in the system, enabling improved operating performance for a comparable coupling over a system where during operation significant variations are experienced in the coupling between the primary and receiver pads.
  • a further problem to be solved is the need to be able to couple to vehicles or appliances with varying ground clearances, which largely determines the distance between the charging pad on the ground or as part of a primary structure (such as a mat or other surface) and the secondary pad of a particular vehicle or other device.
  • a primary structure such as a mat or other surface
  • VA magnetic field leakage
  • a further problem may occur if the primary and secondary inductive pads are polarised but oriented at an angle of 90 degrees to each other such that there is no coupling, and thus no possibility of power transfer.
  • the pad on the ground may have a completely different structure to the vehicle pickup, and/or may be operated as a single phase, two phase or multiphase system to produce substantially different field flux shapes within the space between the two coupled pads under time varying conditions. Under such conditions the ability of a fixed magnetic structure to capture power is limited.
  • Embodiments of WO 2011/16737 provide a magnetic flux pad for generating or receiving magnetic flux, the pad including a magnetically permeable core, two substantially flat overlapping coils magnetically associated with the core whereby there is substantially no mutual coupling between the coils.
  • the invention broadly provides a magnetic flux pad for generating or receiving magnetic flux, the pad comprising:
  • the coils are preferably positioned proximate to or to abut the core such that the surface of the coils that abuts the core is substantially flat.
  • the coils may have a thickness such that the coils do not lie entirely within a single plane. Further, as will be appreciated, at least in the region where the coils overlap, there will be some deviation out-of-plane. References to being “in substantially the same plane” are to be interpreted subject to these limitations throughout the specification.
  • each coil in use is substantially decoupled from all other coils of the at least three coils.
  • the coils are substantially completely magnetically decoupled in use.
  • the coils partially overlap.
  • the coils are substantially coplanar.
  • the coils are provided on one side of the said permeable core, and a shielding means is provided on the other side of the core.
  • the shielding means comprises a shielding plate made of a suitable material such as aluminium.
  • a dielectric cover is provided on the side of the coils opposite the magnetic core.
  • the flux pad is adapted to receive currents from a power supply which are out of phase with each other to produce a time varying magnetic field which also varies spatially.
  • the field produced by the out-of-phase currents in the coils produces a time varying magnetic field which moves spatially and ultimately between poles of the magnetic field.
  • a magnetic flux pad for generating magnetic flux, the magnetic flux pad being configured to be operable in a plurality of modes so as to control the magnetic flux generated thereby.
  • the magnetic flux pad includes three or more coils, any one or more of the coils capable of being selectively energised, thereby enabling said control to be effected.
  • the coils are substantially magnetically decoupled from one another.
  • any one or combination (including all) of the coils may be selectively energised as desired and depending on the particular implementation.
  • mode or the like is to be interpreted broadly as not only meaning that, say, the pad is capable of switching between two coils being energised and three coils being energised, but additionally or alternatively that different ones of the coils (but the same number), may be energised. For example, different ones or different pairs of a three coil pad may be selectively energised.
  • the flux pad includes three said coils.
  • the provision of three coils strikes a balance between the additional performance and flexibility (provided by the adaptability of the flux) and the additional componentry and complexity thereof (particularly in positioning of the multiple coils).
  • a ferrite arrangement for a magnetic flux pad having at least three coils, the ferrite arrangement comprising a plurality of elongate ferrite elements configured such that the elements are co-aligned with and/or parallel to an imaginary line extending between the centres of at least two of said coils.
  • each array being aligned with the imaginary line between a different pair of coils.
  • the imaginary lines between different coil centres may be parallel in some arrangements (see, for example, FIG. 5 ). Consequently, the same array (but extended perpendicular to the orientation of the ferrite element lengths) may be used for different pairs of coils.
  • the arrangement comprises (or when assembled forms) one or more raised and/or recessed portions provided on the surface of the ferrites configured to receive the coils.
  • raised ferrite portion(s) may be provided at an outer edge of one or more of the coils.
  • a raised portion may be provided at a centre of one or more the coils.
  • Other positions of raised portions are also possible, as are recessed portions.
  • the provision of raised and/or recessed portions can be used to further adapt the flux to conform to a desired pattern.
  • the extent or combined operating area of the ferrite arrangement is commensurate with that of the coils.
  • the ferrite material extends beyond the extent of the coils.
  • the increased extent of the provision of ferrites is provided at edges of the coils that cross the imaginary line (or are proximate thereto) but that are at the outer extremities of the coil/ferrite arrangement.
  • the coils may extend beyond the extent of the ferrites.
  • Such arrangements of the ferrites and coils can improve efficiency and reduce the amount of ferrite material required because it is believed that only ferrite provided substantially along the imaginary lines will add to mutual inductance, ferrite material elsewhere simply adding to inductance. Extending the ferrite material beyond the extent of the coils along the imaginary lines can serve to capture flux spill out or over.
  • This aspect of the invention may comprise only two coils and is not to be limited as requiring three or more coils.
  • the ferrite arrangement is configured for use in the magnetic flux pad of the first and second aspects.
  • the invention provides power supply apparatus for an inductive power transfer system, the power supply apparatus comprising:
  • the power supply is adapted to provide a current in any one coil so as to have a different phase to a current in all respective other coils in use.
  • each coil Providing currents with different phases in each coil and adjusting the overlap between the coils, enables each coil to be substantially decoupled from all other coils.
  • the power supply is adapted to adjust the phase to produce a field that varies with time and with spatial position on the pad.
  • the apparatus comprises means to detect where a field is or is not required in the vicinity of the pad and adjust the phase and/or amplitude of the current in at least one of said coils in response thereto.
  • the means to detect is adapted to adjust a relative phase between at least a first of said coils and at least a second of said coils.
  • the power supply comprises an inverter for each coil.
  • the power supply operates two of three inverters to be synchronised with each other such that in one mode of operation the power supply produces a current in a first one of said coils (preferably any one said coils) which is 90° out of phase with the current in a second one of said coils.
  • the power supply operates one of three inverters to produce a current in one of said coils, preferably any one said coils. Where different ones of said coils may be driven independently of the other coils, preferably the current is produced in the coil that is in closest proximity to a coil on a vehicle.
  • the magnetic flux pad produces a sliding time varying magnetic field.
  • the power supply operates at least one pair of the at least three coils 180° out of phase with each other.
  • a common inverter may be used, or two inverters, one driving each coil.
  • the present invention provides all of the flexibility and functionality described in WO 2011/16737 but provides additional functionality and flexibility by enabling additional single coils or pairs of coils that may be energised, as well as enabling higher numbers of coils to be energised, thereby enabling the flux to be better tailored and improve power transfer.
  • the coils energised may be selected at least in part on the required rate of power transfer or the relative position between the pickup and the charging pad.
  • the invention provides power supply apparatus for an inductive power transfer system, the power supply apparatus comprising:
  • the magnetic flux pad may be configured to be operable in the plurality of modes by selectively energising any one or combination of at least three coils of the magnetic flux pad. Further, the particular coils energised may be varied.
  • the invention broadly provides a method for providing an IPT magnetic flux pad having at least three coils in which there is no mutual magnetic coupling between the coils, the method comprising the steps of:
  • the absence of mutual coupling is detected by detecting when an open circuit voltage induced in a first one of the coils by energisation of at least one (but preferably all) of the other coils is minimised.
  • Energisation of the other coils may comprise energising each coil in turn and/or energising multiple coils simultaneously and/or energising each coil as they would be energised in normal use, including with varying phases between the coils.
  • overlap determination is achieved by considering pairs of said at least three coils in turn (i.e., for an arrangement having three coils, evaluating coil 1 against coil 2 , coil 2 against coil 3 , and coil 3 against coil 1 ).
  • the method comprises detecting an open circuit voltage induced in a second one of the coils substantially simultaneously (or at least subject to the same operating conditions) as when the open circuit voltage is detected for the first coil. This may similarly be performed for the third (and more) of said plurality of coils.
  • the invention provides a method of generating magnetic flux, the method comprising:
  • said selectively energising may comprise energising any subset of the coils, or all of the coils.
  • said selectively energising comprises switching between energising a first subset of coil(s) and a second subset of coil(s).
  • the first and second subsets may comprise the same or a different number of coils. Further, one or more coils may be common to both subsets.
  • Additional or alternative subsets of coils may additionally or alternatively be energised. Further, one or more of said subsets may comprise all said coils.
  • the invention may broadly be said to consist in a magnetic flux pad for generating or receiving magnetic flux, the pad comprising:
  • the power supply or pickup controller is operable to operable to selectively conduct with the coils to energise or receive power from any one or more of the coils.
  • the power supply or pickup controller is operable to sequentially energise or receive power from the at least three coils.
  • the power supply or pickup controller is operable to independently control the phase, magnitude and/or frequency of current in each of the at least three coils.
  • the at least three coils are substantially mutually decoupled from one another.
  • the at least three coils partially overlap.
  • the at least three coils are spaced substantially equidistantly from one another.
  • the magnetic flux pad comprises three substantially mutually decoupled coils.
  • the magnetic flux pad is operable in a plurality of modes comprising at least two of:
  • the magnetic flux pad further comprises a magnetically permeable core, wherein the at least three coils are magnetically associated with the core.
  • the magnetic flux pad comprises a further coil disposed substantially centrally and encircling or partially overlapping the at least three coils.
  • the further coil is substantially mutually decoupled from the at least three coils in at least one mode of operation.
  • the magnetic flux pad comprises:
  • the power supply or pickup controller is operable to independently control the magnitude, phase, and/or frequency of current in each coil.
  • the flux pad is operable in at least a three-phase mode.
  • the invention may broadly be said to consist in a magnetic flux pad for receiving magnetic flux and supplying power to a load, the magnetic flux pad being configured to be operable in a plurality of modes so as to control the magnetic flux received thereby, and comprising three or more coils capable of being selectively operated to enable said control to be effected.
  • the invention may broadly be said to consist in a pickup apparatus for an inductive power transfer system, the pickup apparatus comprising:
  • FIG. 1 is a side view and a plan view respectively of a magnetic flux pad
  • FIG. 2 is a side view and plan view respectively of the pad of FIG. 1 including a quadrature coil;
  • FIG. 3 is a side view and plan view respectively of an alternative form of magnetic flux pad
  • FIG. 4 (a) is a plan view of a magnetic flux pad according to a first embodiment of the invention; and (b) is a plan view of a variation of the first embodiment;
  • FIG. 5 is a plan view of a magnetic flux pad according to a second embodiment of the invention.
  • FIG. 6 is a schematic power supply circuit for a known 2 coil pad with mutually decoupled coils
  • FIG. 7 is a schematic power supply circuit for a three coil mutually decoupled pad
  • FIG. 8 is a schematic receiver circuit for a three coil pad with mutually decoupled coils which can both receive and reverse power flow to and from the load;
  • FIG. 9 is a schematic circuit for a three coil pad with mutually decoupled coils which can independently decouple any of the coils and control power flow to the load;
  • FIG. 10 is a plan view of a magnetic flux pad according to a third embodiment of the invention.
  • FIG. 11 is a plan view of a magnetic flux pad according to a fourth embodiment of the invention.
  • FIG. 12 shows plan views of two further embodiments of magnetic flux pads according to the invention.
  • FIG. 13 shows plan views of five further embodiments of magnetic flux pads according to the invention, comprising variations of the embodiments of FIG. 4 ;
  • FIG. 14 shows plan views of four further embodiments of magnetic flux pads according to the invention, comprising sub-optimal variations of the embodiments of FIG. 4 .
  • FIGS. 1 to 3 are prior art arrangements taken from the aforementioned International Patent Publication No. WO 2011/16737.
  • FIG. 1 a prior art magnetic flux pad construction is shown.
  • this general construction is referred to herein as a DDP pad, and is generally referenced DDP in the relevant drawing figures.
  • the DDP pad shown in FIG. 1 generally comprises two substantially coplanar coils referenced 2 and 3 which are magnetically associated with, and sit on top of, a core 4 .
  • the core 4 may consist of a plurality of individual lengths of permeable material such as ferrite strips or bars 5 which are arranged parallel to each other but spaced apart.
  • the pad construction may include a spacer 6 on which the core is located, and a plate 7 below the spacer.
  • a cover 8 may be provided on the other surface of the flat coils 2 and 3 .
  • Padding 9 may be provided about the periphery of the pad.
  • the coils 2 and 3 each define a pole area 10 and 11 respectively.
  • This DDP pad construction shows very good characteristics suitable for IPT power transfer applications such as vehicle charging.
  • the coils 2 , 3 may be connected out of phase and driven by a single inverter to produce a stationary time varying magnetic field to couple to a receiver (which may for example be of substantially the same magnetic design) at distances suitable for electric vehicle power transfer with good coupling.
  • FIG. 2 the DDP construction of FIG. 1 is shown but further including a quadrature coil 12 (referred to herein as a DDPQ pad).
  • the quadrature coil extends the power transfer profile when there is lateral movement of the construction shown in FIG. 2 with respect to a flux generator such as the DDP pad of FIG. 1 when energised by an appropriate inverter.
  • the quadrature coil allows power to be extracted from the “vertical” component of the magnetic field that the receiver pad intercepts while the other coils 2 , 3 facilitate power extraction from the “horizontal” component of the flux intercepted. Therefore, the construction of FIG. 2 is suited as a flux receiver.
  • FIG. 3 another construction is shown which is referred to in this document as a bi-polar pad or, alternatively, as a BPP pad.
  • the BPP pad has a similar construction to the DDP pad discussed with respect to FIGS. 1 and 2 above as it enables excellent coupling to secondary receivers at distances suitable for charging and powering of electric vehicles.
  • the BPP pad consists, from bottom up, of an aluminium plate 7 , a dielectric spacer 6 , a core 4 comprising four rows of ferrite bars 5 (referred to herein as ferrites), two flat substantially coplanar, yet overlapping and ideally “rectangular” shaped coils 2 , 3 (although in practice these are more oval due to the ease in winding Litz wire) spread out in the lateral direction, and a dielectric cover 8 .
  • the core 4 acts as a shield so that ideally all flux is directed away form the core 4 through the top of the pad.
  • the plate 7 merely acts to a) eliminate any small stray or spurious fields that may be present beneath the core 4 in certain environments, and b) provide additional structural strength.
  • Table A1 provides example dimensions of a working prototype of a BPP pad.
  • Tables A2 and A3 provide example dimensions of the DPP pad of FIG. 1 and the DDPQ pad of FIG. 3 , respectively.
  • the magnetic structure of the BPP of FIG. 3 is designed so that there is substantially no mutual coupling between either of the coils 2 , 3 in the primary, as described later. This allows the coils to be driven independently at any magnitude or phase without coupling voltage into each other which if present would oppose the power output of such a coil.
  • the two coils within the BPP can be driven using two separate but synchronised inverters operating with known current magnitude and phase difference as shown conceptually in FIG. 6 .
  • the switches in the H-bridge inverter of FIG. 6 are shown as FETs. In practice these switches may comprise an IGBT with a suitable inverse parallel diode, or SiC JFET and SiC diode or other suitable arrangement as desired.
  • the power supply tuning arrangement of FIG. 6 uses a known LCL topology (see, for example, WO 2007/100265) at the output of the each inverter's H-bridge.
  • the inductances in each of the coils of FIG. 3 are assumed to be identical based on them having the same shape and turns ratio.
  • This inductance (as seen by the supply and including lead lengths and any other compensation elements such as a series capacitor which may be required to limit voltage across the power supply tuning capacitor C p ) is given a value of L 1 .
  • the primary inductor (L p ) is chosen to be identical to L 1 , and the tuning capacitor C p has an identical reactance at the designed frequency of the supply.
  • Subscripts 2 and 3 represent the circuit attached to coils labelled 2 and 3 in the BPP of FIG. 3 .
  • the two inverters shown in FIG. 6 may be synchronised but operated so as to produce currents with the same RMS magnitude, but operating 90 degrees out of phase in each of the coils 2 , 3 .
  • a spatially varying and time varying magnetic field is created rather than the stationary time varying magnetic field of the DDP.
  • the spatial variation in the field of the BPP may appear as a sliding movement in alternate directions between the poles of the coils 2 , 3 .
  • the field may be directed in response to the output of a sensor for example which may sense where greater field strength is required, or where the field strength should be reduced. Also, the field strength may be time varying but spatially stationary dependent on where across the pad the field is required.
  • This particular single phase operating mode is a second possible mode of operation to simplify the electronic control and power conversion that will produce a stationary time varying field as for the DDP.
  • WO 2011/16737 further provides guidance on preferred configurations of the ferrite strips 5 above which the coils 2 , 3 are placed in the BPP pad.
  • the ferrite strips 5 are used to enhance power transfer and ensure that a predominately single sided flux field is created to best couple to the secondary power receiver, while ensuring that a minimal amount of ferrite is used to keep weight to a minimum and restrict the inductance of the pad. In such a sliding field it is shown that the ferrite strips should preferably extend under the winding coils otherwise the field may not be forced upwards towards the receiver.
  • FIG. 4( a ) shows a plan view of a variation of the FIG. 3 arrangement according to an embodiment of the invention.
  • the magnetic flux pad of FIG. 4( a ) includes three coils 2 , 3 , 3 a and a modified ferrite 5 arrangement. Otherwise, the construction of the pad of FIG. 4( a ) is generally in accordance with that of the BPP pad of FIG. 3 , including, from the bottom upwards (when comparing with the upper drawing of FIG. 3) , base plate 7 (preferably aluminium), spacer 6 (preferably dielectric), a core 4 comprising ferrite material 5 , substantially co-planar coils 2 , 3 , 3 a and a cover 8 (preferably dielectric).
  • the configuration of the core 4 has been adapted and includes three sets of ferrites 5 arranged with an offset of or substantially of 60° between each set, wherein each the three ferrite sets extends substantially parallel with an axis extending between the centre of respective pairs of coils 2 , 3 and 3 a.
  • FIG. 4( b ) illustrates a variation of the embodiment of FIG. 4( a ), in which the core comprises a single ferrite strip or bar 5 along each of the imaginary lines between the centres of the coils, forming at equilateral triangle in the centre.
  • the plate 7 in this embodiment has a shape corresponding substantially with the outer perimeter of overlapping coils 2 , 3 and 3 a , including padding.
  • FIG. 5 shows a plan view of another embodiment of the invention.
  • the arrangement of FIG. 5 is substantially the same as those of FIG. 4 but includes four coils 2 , 3 , 3 a , 3 b and a modified ferrite 5 arrangement within the core 4 .
  • the additional coil 3 b may be placed above, below or between coils 2 , 3 and 3 a .
  • a ferrite lattice is used with one set of ferrites offset from the other by or substantially by 90° to form a grid.
  • the extent of overlap between the coils may be varied to obtain the desired decoupling. More particularly, one or more of the at least three coils may be energised with a predetermined current at a fixed or respective fixed frequency and the overlap with the other or other ones of the at least three coils varied so as to minimise the voltage in the other or other ones of the at least three coils.
  • the ferrites 5 should first be fixed in place (since any change to the position and shape of ferrites 5 will impact on the overlap required between the coils necessary to ensure mutual coupling is minimised).
  • the shape and size of each of coils 2 , 3 and 3 A should preferably be identical (although the invention is not limited thereto).
  • coil 3 can be moved into the relative position shown while energising coil 2 .
  • the open circuit voltage coupled into coil 3 from the energisation of coil 2 can be easily measured and with suitable movement of coil 3 relative to coil 2 can be reduced to a minimum (ideally zero), to determine the ideal relative position of both coils.
  • coil 3 a can be added generally in the position shown on FIG. 4( a ). Coil 3 a can now be energised and the voltages coupled into coils 2 and 3 monitored. By adjusting the position of coil 3 a relative to both coils 2 and 3 the coupled voltages should be reduced to a minimum (ideally zero), at which point its position is fixed.
  • FIGS. 4 and 5 While circular coils are shown in FIGS. 4 and 5 , the invention is not limited to coils of that shape.
  • the coils may alternatively have a generally oval, square or rectangular configuration.
  • different coils within the same pad may have different configurations.
  • coil 2 may be oval and coils 3 , 3 a circular.
  • the lateral spacing of the circular coils of the Figures may be substantially equidistant such that imaginary lines or axes extending between the centres of adjacent coils may form a substantially equilateral triangle or square shape, this need not necessarily be the case.
  • ferrite 5 arrangements have been shown in FIGS. 4 and 5 , the invention is not limited thereto.
  • Other arrangements may be devised to direct the field in a desired manner, or more particularly to provide a path of low magnetic reluctance between the poles of the three or more mutually decoupled coils, including a single sheet of ferrite material of sufficient size.
  • ferrite strips as opposed to a sheet of ferrite material provides similar performance in terms of controlling the flux and so appropriately configured strips may be favoured to reduce the cost and weight thereof.
  • a core comprising a sheet of ferrite material may be thinner and preferred in other applications, and may be shaped to ensure that it provides a path of low magnetic reluctance only between the poles.
  • each array being configured to be so aligned with one or more pairs of said coils (i.e., with the imaginary lines or axes extending between coil centres).
  • the ferrite material it is preferable for the ferrite material to extend beyond the edges of the coils (as shown in at least FIGS. 4 and 5 ).
  • the invention is not limited thereto and may be configured differently depending on the particular application and the coils may in fact extend over a larger area than the ferrite material.
  • the ferrite material extends beyond the outer extremity of the coils in selected regions of the coils only, the selected regions being at or proximate to where said imaginary lines cross said coils (see FIG. 3 ). Additionally or alternatively, one or more of the coils may extend beyond the extent of the ferrites, preferably outside of said previously mentioned selected regions (again, see FIG. 3 ).
  • the ferrites are configured to form the desired pattern in a single layer.
  • the ferrites may be arranged such that the ferrites extending up and down the page (the vertical ferrites) are as shown and the left to right ferrites (the horizontal ferrites) are then each formed by a plurality of shorter ferrites that extend across the gap between the vertical ferrites, preferably such that the ends of the horizontal elements abut or substantially abut the adjacent vertical ferrites.
  • Forming the ferrites in this manner reduces the thickness and weight of the core.
  • the ferrites may be otherwise configured.
  • the strips may have a varying thickness such that they are thinner at the regions of overlap. Reducing the thickness as a step enables the different ferrite elements to interlock.
  • each strip of ferrite may be formed from more than one piece of ferrite material.
  • smaller strips or pieces of ferrite material may abut or substantially abut one another to form each larger piece.
  • a ferrite arrangement may be formed from one or more sheets of ferrite material with portions thereof removed as desired.
  • FIG. 7 shows a possible power supply arrangement necessary for driving the pad shown in FIG. 4 .
  • subscripts 2 , 3 and 3 A represent the inverter topology connection to coils 2 , 3 and 3 A in FIG. 4 .
  • an advantage of using at least three coils of the present invention is that the pad may be used in multiple modes.
  • a single coil of at least three coils of a charging pad may be activated to couple power to a small receiver on a small utility vehicle, where the chosen coil to be activated depends on the coil which is best coupled (i.e. best aligned) to the receiver on the vehicle.
  • all coils may be energised in phase with each other, creating a larger stationary time varying field to power a large vehicle or one requiring faster charge.
  • said coils (preferably three) may be used in a three phase system (i.e. each 120 degrees out of phase) to create a sliding spatially varying and time varying field or multiple selected coils may be energised in a single phase system (i.e., to create a stationary time varying field).
  • coils of the charging pad may be energised dependent on the orientation and/or alignment of the pick-up (e.g. on the vehicle to be charged).
  • all or a subset of the coils may be energised in use.
  • pairs of coils may be energised, per the BPP pad arrangement of FIG. 3 , to produce a field most effectively received by a pickup.
  • the pair of coils energised may be varied, for example, to modify the field to compensate for movement of the pickup.
  • pairs of coils of a pad containing at least three coils may be selectively energised (including sequentially) if that produces the most effective field.
  • the presence of at least three coils further enables improved steering of the field generated by the charging pad.
  • different coils may be energised to different levels, thereby “steering” the field in a selected direction to, say, accommodate misalignment of a pickup with a charging pad, such as due to variations in parking of vehicles to which a charge is to be provided.
  • the use of at least three coils can additionally or alternatively assist in sensing a location of a vehicle pickup so that an appropriate (ideally optimal) charging regime can be implemented, depending at least in part on the detected location. While this is achievable to some extent using the arrangements described in WO 2011/16737, the inclusion of additional coils provides greater accuracy of detected position and enables position to be determined in at least two dimensions.
  • additional, decoupled coils provides for increased flexibility in the manners in which the apparatus of the invention may be used by enabling all or a subset of the coils to be used and further provides for improved power transfer by varying the mode of operation and/or through the improved steering/positioning of the field achieved (improved in terms of being controllable in multiple dimensions and/or across a larger area and/or better determination of pickup position and/or adaptation of the field as a result thereof).
  • embodiments of the invention have particular application for use as a “charging pad” (i.e., the primary side winding) but the same or similar arrangements may be used for the pickup, again with improved power transfer characteristics as a result of the decoupling between coils of the pickup.
  • the coils would be electrically coupled to and controlled by a pick-up controller, rather than a power supply, the pickup controller being operable to deliver power received from the pickup coils to a load.
  • the controller would typically comprise a controllable rectifier or rectifiers, rather than the inverters of a power supply.
  • the circuit of FIG. 8 which is essentially identical to the that of FIG. 7 , could also be used at the output of a pad to enable power transfer to a load connected across the DC capacitor which in such a case could also be across the battery of an electric vehicle.
  • the power available from each receiver coil can be monitored, and if small, the bottom switches in each inverter bridge can be closed to decouple that receiver coil and remove any losses which would otherwise occur from its operation.
  • the primary and/or secondary pads may be reversible, wherein the pad may be operated to selectively conduct with the coils to receive or deliver power from/to another pad.
  • the circuit of FIG. 8 could easily be used to reverse the power flow back to the primary but in order to synchronise this power flow back into mains utility supply, the three phase rectifier of FIG. 7 would need to be replaced with a suitable reversible rectifier.
  • FIG. 9 a simpler secondary circuit can be used, an example of which is shown in FIG. 9 .
  • a tuning capacitor can be used either in series or parallel or both to bring each AC circuit to resonance.
  • a parallel resonant circuit is shown with optional series capacitance to boost the current from each coil if required at design.
  • the output of each of these tuned circuits is then rectified, filtered (using the common L dc and C dc ) and regulated using switch S to the load.
  • the two switches at the base of each rectifier can be turned on and used to decouple that coil from the circuit without affecting the power transfer in either of the remaining coils, thereby substantially removing any loss associated with that circuit.
  • This power transfer from each coil can be easily determined by measuring the magnitude of the AC current in each of the rectifiers.
  • the output diode ensures that the energy in C dc is not discharged undesirably through any of the switches in the circuit when these switches are turned on.
  • Switch S is used to both regulate the total power flow and decouple all three coils if and when required.
  • the IPT pad of the present invention preferably couples power to the secondary or receiving pad as effectively as possible, irrespective of the secondary pad's magnetic configuration, orientation, and displacement (lateral or otherwise).
  • the secondary pad may be integrated within a vehicle, mobile telephone, laptop or other such electrical device, providing little if any control over these variable factors. That is, the primary pad is preferably designed to be universal or near-universal in that it is adapted to transfer power to a range of possible secondary pads and/or under a wide range of conditions which could be reasonably anticipated in a particular application.
  • the orientation of this device is of equal concern.
  • the primary coils may be energised to ensure best coupling and in the case where the coils are separately controlled either a single phase polarised coil with best orientation can be energised, or multiphase operation can be used to transfer power while ensuring greatest coupling and power transfer with minimal leakage for the designated application. Variations in ground clearance, alignment and rotation may all affect the choice of which coils are selected under what conditions.
  • the coils in the primary ground side have minimal mutual coupling between them, so that any configuration is acceptable and can be used without detrimental effects such as coupled voltages from the energising of neighbouring coils appearing in nearby coils and disrupting power flow and the generation of the desired flux shape.
  • some mutual cross-coupling may be allowable in certain configurations if is sufficiently small, provided the power coupling between the apparatus is controllable and leakage is contained as required for the application.
  • the ferrite strips 5 are not essential to the present invention, and may in particular be omitted where a double-sided flux field may be tolerable or even desirable.
  • FIGS. 10 and 11 show variations of the embodiments of FIGS. 4 and 5 , respectively, in which the ferrite strips 5 are omitted.
  • a backplate made of a conductive material such as aluminium or copper provided a suitable distance from the coils may act as a shield while minimising losses.
  • the plate 7 may therefore comprise a ferrite loaded printed circuit board (PCB) and/or an aluminium plate, for example.
  • PCB printed circuit board
  • the fields below the structure may not be able to couple undesirably to any structure, and therefore will not cause any losses. While having fields present on both sides of the primary reduces coupling to a secondary device, it does not produce any significant loss and may therefore be preferred in some circumstances to minimise the cost of producing the primary pad.
  • FIGS. 12( a ) and 12 ( b ) show two variations of a further embodiment of an IPT pad according to the present invention, with and without ferrite strips 5 .
  • the pad according to this embodiment comprises four coils 2 , 3 , 3 a and 3 b with a quadrature coil 12 . If the four circular coils 2 , 3 , 3 a and 3 b are thought of as each having a centre collectively defining the vertices of a square, diagonally opposing coils of the square abut each other without overlapping to form two orthogonal DDP pairs (as described above with respect to FIGS. 1 and 2) operating as dipoles.
  • Each coil of the DDP pairs overlaps both the coils of the orthogonal DDP pair, and the two DDP pairs are accordingly mutually decoupled.
  • the quadrature coil 12 is also mutually decoupled from both of the DDP pairs.
  • the DDP pairs and the quadrature coil are all independent and may also be operated with different magnitude, phase or frequency without interfering with each other, to shape the field as required.
  • the DDP or quadrature coils can be separately tuned at different or similar frequencies and power can be extracted as and when desired based on the application.
  • the DDP pairs may be operated in phase with each other, generating a stationary time varying magnetic field.
  • one pair of diagonally opposing DDP coils may be energised out of phase with the other pair.
  • only one DDP may be energised.
  • the quadrature coil 12 may be energised simultaneously with either or both of the DDP pairs.
  • the mode of operation and, where appropriate, coils energised are preferably chosen to produce a field most effectively received by a pickup.
  • the IPT system is preferably capable of switching between any such mode as required to operate in the most efficient way, but may be limited to a single mode or a selection of modes to simplify the power supply design and/or control.
  • FIGS. 12( c )-( e ) show further variations of the embodiments of FIGS. 12( a ) and ( b ).
  • the embodiment of FIG. 12( c ) omits the quadrature coil.
  • FIG. 12( d ) illustrates that the coils of each DDP pair need not necessarily be the same size, yet are still capable of being mutually decoupled.
  • a quadrature coil 12 can also be added to this embodiment as shown in FIG. 12( e ). Because the DDP pairs of coils are operated as dipoles, the quadrature coil 12 is mutually decoupled from both DDP pairs in this embodiment.
  • An IPT pad according to the present invention is thus preferably designed to have a mutual coupling of less than about 10% in the absence of a load or external ferrite material, and more particularly less than about 2% or even 1%.
  • the phrases “mutually decoupled”, “no mutual coupling” and the like are intended to encompass such mutual couplings.
  • FIGS. 13 and 14 show embodiments of the invention in which there may be a low level of mutual coupling, of up to about 20% for example.
  • FIGS. 13( a )- 13 ( e ) show embodiments comprising further variations of the three-coil IPT pad of FIG. 4 .
  • the IPT pad of FIG. 13( a ) further comprises a further coil 13 which is not ideally mutually decoupled, in this case entirely encircling coils 2 , 3 and 3 a .
  • the further coil 13 in this embodiment is preferably disposed such that its centre or pole is substantially central with respect to coils 2 , 3 and 3 a which are, preferably, mutually decoupled from one another.
  • the central coil 13 in this embodiment encircles the other coils, in other embodiments the substantially central coil 13 may circumscribe or partially overlap the three or more other coils, as described below.
  • the central coil 13 encircles or partially overlaps all of the other coils, it will not be mutually decoupled from those coils in all possible modes of operation.
  • the central coil 13 of FIG. 13( a ) will be substantially mutually decoupled from coils 2 , 3 and 3 a when all three of those coils are energised, but will not typically be mutually decoupled when only coils 2 and 3 are energised, for example,
  • the IPT pad of FIG. 13( a ) also omits the core or ferrite strips 5 of the embodiment of FIG. 4 .
  • the square shape of the plate 7 can also be seen to differ from the triangular plate 7 of FIG. 4 to accommodate the central coil 13 .
  • FIG. 13( b ) The embodiment of FIG. 13( b ) is similar to that of FIG. 13( a ), but comprises a lattice or grid of substantially orthogonal ferrite strips 5 . It will be apparent that the ferrite strips 5 thus need not necessarily extend parallel to imaginary lines between the centres of coils 2 , 3 and 3 a as shown in FIG. 4 . As previously described, the core may alternatively comprise a sheet of ferrite material.
  • FIG. 13( c ) comprises a further modification with respect to FIG. 13( b ), in that the ferrite strips 5 extend beyond the outer circumference of central coil 13 . If the ferrite strips 5 terminate within the central coil 13 then the field will radiate, and the elongated ferrite strips 5 of this embodiment will thus generally be preferred.
  • FIGS. 13( d ) and 13 ( e ) show further variations of the three-coil pad of FIG. 4 , further comprising a central coil 13 which partially encircles coils 2 , 3 and 3 a .
  • FIG. 13( d ) shows an embodiment of an IPT pad without ferrite strips 5
  • FIG. 13( e ) comprises a lattice of ferrite strips 5 extending to, or slightly beyond, the outer circumference of coils 2 , 3 and 3 a.
  • FIGS. 14( a ) to 14 ( d ) illustrate some sub-optimal variations of the three-coil embodiments of FIG. 4 , by way of example.
  • the coils 2 , 3 and 3 a do not overlap, and will therefore have mutual coupling.
  • the coils will all be mutually decoupled from each other to ensure that each coil can be easily tuned to receive power at a selected frequency, and that power transfer is maximised. Under such conditions, when a coil is not receiving power it can be switched off without impacting the operation of the other coils, to reduce any operating loss. Nevertheless, if the secondary coils are not perfectly mutually coupled (independent), then provided the operating circuit tuning Q (reactance of the coil divided by the load of the circuit) is low, then nominal tuning can be achieved and operation can still arise despite there being some mutual coupling between neighbouring coils. Such coils can also be switched out and while this may slightly impact the power transfer in adjacent coils, this can be compensated for by operation of the primary ground coils increasing or decreasing its driving VA or by adjusting a secondary regulator to modify the power to the load.
  • a further embodiment of the present invention comprising three or more mutually decoupled coils
  • some of the coils may be designed and tuned for operation at 40 kHz while others may be tuned at 80 kHz, enabling coupling to different magnetic structures at different tuned frequencies.
  • some coils may be tuned at 800 MHz while others may be tuned to 2.4 GHz (both unlicensed bands) to achieve the same for smaller appliances or mobile consumer electronics devices, for example.
  • a primary magnetic flux pad may be provided in a mouse pad to power or charge a wireless mouse, or may be integrated in the mouse to receive power from a known primary pad.
  • the invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.
US14/379,068 2012-02-16 2013-02-15 Multiple coil flux pad Abandoned US20150236513A1 (en)

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US11581124B2 (en) 2023-02-14
KR20140129172A (ko) 2014-11-06
EP2815484B1 (en) 2022-11-30
EP2815484A1 (en) 2014-12-24
JP2019009461A (ja) 2019-01-17
CN112046305A (zh) 2020-12-08
JP6608498B2 (ja) 2019-11-20
CN104380567A (zh) 2015-02-25
WO2013122483A1 (en) 2013-08-22
EP2815484A4 (en) 2015-09-23
IN2014DN07034A (ja) 2015-04-10
US20200366132A1 (en) 2020-11-19
JP2015508940A (ja) 2015-03-23

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