Power transfer device

• US 4,654,573 A
• Filed: 05/17/1985
• Issued: 03/31/1987
• Est. Priority Date: 05/17/1985
• Status: Expired due to Fees

• Current Assignee: Security Pacific Capital Corporation (Bank of America Corp.), Blue Marble Holdings Corp. (Harvard Corporation), Kleiner Perkins Caufield & Byers
• Original Assignee: Flexible Manufacturing Systems, Inc.
• Inventors: Biche, Michael R., Rough, J. Kirkwood H., Krolak, Michael
• Primary Examiner(s): HICKEY, ROBERT
• Application Number:
  US06/735,481
• Time in Patent Office: 683 Days
• Field of Search: 320/2-5, 320/20, 320/21, 320/39, 320/40, 320/31, 363/15, 363/18
• US Class Current: 320/108
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/527 Voltage
• CPC Class Codes: B60L 2240/529 Current
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 53/122 Circuits or methods for driving the primary coil, e.g. supplying electric power to the coil
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 58/25 by controlling the electric load
• CPC Class Codes: H02J 50/12 of the resonant type
• 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 7/007194 of the battery
• CPC Class Codes: H02M 7/10 arranged for operation in series, e.g. for multiplication of voltage
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 320/25 : Optical coupler

Abstract

Apparatus for transferring electrical power between a power supplying apparatus and power consuming apparatus and having a separable high frequency transformer with a primary permanently mounted to the power supply apparatus and a secondary mounted about the power consuming apparatus. A charging control circuit mounted on the consuming apparatus, e.g. a mobile vehicle includes means for detecting current and voltage delivered through the transformer, and also for monitoring storage batteries within the vehicle. The power supply apparatus includes a power supply circuit comprising a ferrite core transformer and capacitor forming a parallel resonant circuit. The primaries of the transformer are alternately driven by a driver about opposing polarities. The drivers are controlled by a voltage-controlled pulse-width modulator which provides a square wave input to the drivers to cause them to alternatively energize the ferrite core transformer. Power is transferred across the inductor to the resonant circuit as portions of a sine wave. The power supply circuit also includes an internal current sensing circuit to shut current build-up down when current in the resonant circuit becomes too high, and an external control loop which senses power demands of the charging control circuit delivered via an optical communications link within the separable transformer.

Claims

1. Apparatus for a transfer of power between a power supplying apparatus and power consuming apparatus comprising:

a separable transformer means including a first transformer half and a second transformer half adapted for magnetic coupling, each of said halves having a core of ferrite material for operating at a frequency of at least approximately twenty-five kilohertz;

a charging control circuit connected to the first transformer half and to a plurality of storage batteries for determining an amount of current flowing through the transformer and comparing said amount of current with an amount of charge needed by said plurality of storage batteries to establish a power demand signal;

a first optical communications means connected to the charging control circuit for transmitting said power demand signal;

a power supply circuit having drive power transistors connected to said second transformer half and including transfer means to transfer energy at a frequency of at least approximately twenty-five kilohertz through said transformer; and

a second communications means connected to said power supply circuit for receiving a demand signal responsive to said power demand signal from said first communication means to vary an on/off cycle of said drive power transistors whereby an amount of power delivered through said transformer may be regulated thereby.

2. Apparatus for transfer of power between a power supply apparatus and a power consumming apparatus comprising:

a separable transformer comprising a first and a second pot core half, each of said pot core halves including a plurality of windings surrounded by an insulating material;

a charging control circuit, connected to the first pot core half and to at least one storage cell and including at least a first sensing means for sensing a flow of current through the transformer and generating a control signal;

a power supply circuit connected to said second half core including at least a first regulating means for regulating a flow of current through the transformer to said cell, the power supply circuit including a resonant tank circuit means for inductively transferring power at a sine wave, said power being transferred at a first frequency; and

an optical transmission link for coupling the control signal with said first regulating means of the power supply circuit.

3. The apparatus of claim 2 wherein said first-frequency of power transfer is approximately 25 KHz.

4. The apparatus of claim 2 wherein,

the charging control circuit includes:

a voltage detector means for detecting a voltage across said transformer and said cell;

a voltage integrator means associated with the voltage detector means for determining the magnitude of a voltage across the transformer;

a current detector means for detecting a current through said transformer and said cell;

a current regulator means associated with the current detector means for determining an amount of current flowing through the transformer;

a temperature sensing and correction means for sensing a temperature of said storage cell and for providing an input to the voltage integrator to correct a voltage value stored thereby;

a reference voltage means connected to an output of the voltage and the current integrators for supplying a reference voltage thereto; and

a scale amplifier means having an input connected to an output of the voltage and current integrator means for amplifying said outputs.

5. The apparatus of claim 2 wherein

the optical transmission link includes:

a voltage-to-frequency convertor having an input connected to an output of the charging control circuit and having an output coupled to a LED;

an on/off control means connected to said LED for enabling a light output therefrom, and

a frequency-to-voltage convertor having a frequency input connected to a photodiode, said photodiode positioned to detect a light output of said LED and having a voltage output proportional to a frequency detected by said photodiode, said frequency to voltage convertor being connected to said power supply circuit control means whereby a power demand of the charging control circuit may be communicated to the power supply circuit.

6. The apparatus of claim 2 wherein the power supply circuit includes:

a power source means for delivering a source of low impedance direct current, the means including a charging inductor and rectifier means and an energy storage capacitor means;

a resonant inductor circuit means coupled to the power source means and comprising a first and second primary winding, and a secondary winding, said first primary winding being in resonance with the power source means during 90°

of a period of oscillation thereof, and said second primary winding being in resonance with said power source means during a second 90°

period of oscillation which is 180°

out of phase with said first 90°

period, said secondary being connected to a capacitor forming a tank circuit for storing a discharge of energy from said first and said second primary windings, the tank circuit being connected to the second half core;

a first driver for driving the first primary winding, and a second driver for driving the second primary winding, each driver being alternatively driven by a first and a second decoder driver;

a voltage-controlled pulse-width modulator for producing a square pulse waveform to said decoder drivers;

a flip flop means connected to a start input of the voltage-controlled pulse-width modulator for initiating said pulse generation;

a phase shift and trigger means connected to a control input of the voltage-controlled pulse-width modulator and receiving an input from said resonant tank circuit whereby said voltage-controlled pulse-width modulator is controlled to put out square voltage pulses which are 90°

out of phase with a voltage sine wave circulating in said tank circuit, said pulses produced by said voltage-controlled pulse-width modulator being 90°

; and

a control means connected to said tank circuit and to said control input of the voltage-controlled pulse-width modulator for sensing and controlling a power output of the circuit.

7. The apparatus of claim 6 wherein

the control means includes:

an RMS convertor, connected to an output of said tank circuit;

a summing network, connected to the RMS convertor and to said first sensing means; and

an integrator means for receiving an input from the summing network and providing a voltage output to a control voltage input of the voltage-controlled pulse width modulator whereby a voltage circulating in the resonant tank is compared with a voltage demand of said first sensing means and said pulse width of the voltage-controlled pulse-width modulator may be altered thereby.