Bidirectional power converter

• US 10,128,691 B2
• Filed: 01/23/2018
• Issued: 11/13/2018
• Est. Priority Date: 04/10/2015
• Status: Active Grant

• Current Assignee: PNC Bank National Association (The PNC Financial Services Group, Inc.)
• Original Assignee: Enovate Medical, LLC (Enovate Medical Holdings, LLC)
• Inventors: Blakely, George, Waid, Gordon
• Primary Examiner(s): Houston, Adam
• Application Number:
  US15/878,384
• Publication Number:
  US 20180175657A1
• Time in Patent Office: 294 Days
• Field of Search: 307104, 307108
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/20 using microwaves or radio frequency waves
• CPC Class Codes: H02J 50/80 involving the exchange of data, concerning supply or distribution of electric power, between transmitting devices and receiving devices
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007192 in response to temperature
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 7/5383 in a self-oscillating arrangement H02M7/538 takes precedence
• CPC Class Codes: H02M 7/70 using discharge tubes without control electrode or semiconductor devices without control electrode
• CPC Class Codes: H02M 7/797 using semiconductor devices only
• CPC Class Codes: H04B 1/16 Circuits
• CPC Class Codes: H04B 1/40 Circuits

Abstract

A bidirectional power converter circuit is controlled via a hysteresis loop such that the bidirectional power converter circuit can compensate in near real time for variations and even changes in transmit and receive coil locations without damaging components of the system. Because the bidirectional power converter is capable of both transmitting and receiving power (at different times), one circuit and board may be used as the main component in multiple wireless power converter designs.

Claims

1. A bidirectional power converter operable to provide alternating current (AC) power at an AC terminal of the bidirectional power converter in a transmit mode of the bidirectional power converter and provide direct current (DC) power at a DC output terminal of the bidirectional power converter in a receive mode, the bidirectional power converter comprising:

an oscillator configured to provide a drive signal at a base frequency;

an amplifier configured to receive power from a power source via a DC input terminal of the bidirectional power converter and provide an AC output signal in response to receiving the drive signal when the bidirectional power converter is operating in the transmit mode;

a modulator configured to selectively provide the drive signal from the oscillator to the amplifier as a function of a hysteretic control signal when the bidirectional power converter is operating in the transmit mode;

a hysteretic receiver circuit configured to receive a transmitted control signal and provide the hysteretic control signal to the modulator;

a transmit relay configured to electrically connect the amplifier to the AC terminal of the bidirectional power converter when the bidirectional power converter is operating in the transmit mode and electrically disconnect the amplifier from the AC terminal of the bidirectional power converter when the bidirectional power converter is operating in the receive mode;

a rectifier configured to receive an alternating current power signal from the AC terminal of the bidirectional power converter and provide a DC output to the DC output terminal of the bidirectional power converter when the bidirectional power converter is operating in the receive mode; and

a hysteretic control circuit configured to monitor the DC output and transmit a control signal as a function of the DC output when the bidirectional power converter is operating in the receive mode.

2. The bidirectional power converter of claim 1, wherein the hysteretic control circuit comprises:

a hysteretic controller configured to provide a logic signal, wherein the logic signal is a first binary value when a voltage of the DC output is less than a predetermined threshold and the logic signal is a second binary value when the voltage of the DC output is more than the predetermined threshold and wherein the first binary value is different than the second binary value; and

a coil pulse driver configured to receive the logic signal and generate a magnetic field via a magnetic coupling coil, wherein the generated magnetic field is indicative of the logic signal; and

the hysteretic receiver circuit comprises a magnetic sensor configured to receive a magnetic field and provide the hysteretic control signal to the modulator as a function of the received magnetic field.

3. The bidirectional power converter of claim 1, wherein the hysteretic control circuit comprises:

a hysteretic controller configured to provide a logic signal, wherein the logic signal is a first binary value when a voltage of the DC output is less than a predetermined threshold and the logic signal is a second binary value when the voltage of the DC output is more than the predetermined threshold and wherein the first binary value is different than the second binary value; and

a radio frequency (RF) transmitter configured to receive the logic signal and transmit an RF signal via an antenna, wherein the transmitted RF signal is indicative of the logic signal; and

the hysteretic receiver circuit comprises an RF receiver configured to receive an RF signal and provide the hysteretic control signal to the modulator as a function of the received RF signal.

4. The bidirectional power converter of claim 1, wherein the hysteretic control circuit comprises:

a hysteretic controller configured to provide a logic signal, wherein the logic signal is a first binary value when a voltage of the DC output is less than a predetermined threshold and the logic signal is a second binary value when the voltage of the DC output is more than the predetermined threshold and wherein the first binary value is different than the second binary value; and

an optical transmitter configured to receive the logic signal and transmit an optical signal via an infrared (IR) emitter, wherein the transmitted optical signal is indicative of the logic signal; and

the hysteretic receiver circuit comprises an IR receiver configured to receive an optical signal and provide the hysteretic control signal to the modulator as a function of the received optical signal.

5. The bidirectional power converter of claim 1, further comprising:

a coil connected to the AC terminal of bidirectional power converter, wherein the coil is configured to;

receive the AC output signal from the amplifier and emit a corresponding electromagnetic field when the bidirectional power converter is operating in the transmit mode; and

convert electromagnetic flux into an AC power signal when the bidirectional power converter is operating in the receive mode.

6. The bidirectional power converter of claim 5, wherein the coil comprises:

a wire coil, and

a tuning capacitor connecting the wire coil to the AC terminal of the bidirectional power converter.

7. The bidirectional power converter of claim 1, further comprising:

a DC charge control relay comprising a unified DC terminal, wherein the DC control relay is configured to;

connect to the DC input terminal of the bidirectional power converter and the DC output terminal;

electrically isolate the DC input terminal from the DC output terminal;

electrically connect the DC input terminal to the unified DC terminal when the bidirectional power converter is operating in the transmit mode; and

electrically connect the DC output terminal to the unified DC terminal when the bidirectional power converter is operating in the receive mode.

8. The bidirectional power converter of claim 1, wherein the modulator is an amplitude shift keyed modulator.

9. The bidirectional power converter of claim 1, wherein the amplifier is a full bridge amplifier.

10. The bidirectional power converter of claim 1, wherein the rectifier is a full wave rectifier.

11. The bidirectional power converter of claim 1, wherein the base frequency of the oscillator is approximately 100 kHz.

12. The bidirectional power converter of claim 1, further comprising:

a slow start circuit configured to provide a pulse width modulated signal that increases from zero to one hundred percent duty cycle beginning when the bidirectional power converter begins operating in the transmit mode, wherein the rate of increase is generally linear; and

a one shot timer configured to provide a one shot signal to the modulator when the bidirectional power converter begins operating in the transmit mode and for a predetermined period of time thereafter, wherein;

the modulator is further configured to provide the drive signal from the oscillator to the amplifier when the pulse width modulated signal is on and at least one of the hysteretic control signal and one shot signal are on.

13. The bidirectional power converter of claim 1, further comprising:

a switching regulator configured to generate bias voltages when the bidirectional power converter is receiving power from the power source at the DC input terminal of the bidirectional power converter, wherein the switching regulator provides at least one of the generated bias voltages to;

the oscillator, the amplifier, the modulator, the hysteretic receiver circuit, and the transmit relay, and a slow start circuit, a one shot timer, and a temperature sensor of the bidirectional power converter.

14. The bidirectional power converter of claim 1, further comprising:

a temperature sensor configured to monitor a temperature of the amplifier and provide a temperature sensing signal; and

a control logic configured to provide a modulator enable signal to the modulator as a function of the temperature sensing signal and a direction control signal such that the modulator enable signal is provided when the direction control signal sets the bidirectional power converter in the transmit mode and the temperature sensing signal is indicative of a temperature less than a predetermined temperature, wherein the modulator does not provide the drive signal from the oscillator to the amplifier when the modulator is not receiving the modulator enable signal.

15. The bidirectional power converter of claim 1, further comprising:

a linear regulator configured to receive the DC output from the rectifier and provide bias voltages to the hysteretic control circuit when the bidirectional power converter is operating in the receive mode.

16. The bidirectional power converter of claim 1, further comprising:

a DC filter configured to smooth the DC output provided by the rectifier to the DC output terminal.

17. The bidirectional power converter of claim 1, further comprising:

a plurality of isolators configured to isolate the DC input terminal from the AC terminal and the AC terminal from the DC output terminal of the bidirectional power converter such that the bidirectional power converter is an isolated power source in both the transmit mode and the receive mode.