Electrical charging system having energy coupling arrangement for wireless energy transmission therebetween

• US 9,379,571 B2
• Filed: 04/19/2012
• Issued: 06/28/2016
• Est. Priority Date: 07/11/2011
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Boyer, Richard J., Pasha, Brian D., Fuzo, John Victor
• Primary Examiner(s): Muralidar, Richard V
• Application Number:
  US13/450,881
• Publication Number:
  US 20130015812A1
• Time in Patent Office: 1,531 Days
• Field of Search: 320/108, 320/109, 180/65.1, 180/65.21, 180/65.29
• US Class Current: 1/1
• CPC Class Codes: B60L 2240/62 Vehicle position
• 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 53/126 Methods for pairing a vehicle and a charging station, e.g. establishing a one-to-one relation between a wireless power transmitter and a wireless power receiver
• CPC Class Codes: B60L 53/35 Means for automatic or assisted adjustment of the relative position of charging devices and vehicles
• CPC Class Codes: B60L 53/38 specially adapted for charging by inductive energy transfer
• CPC Class Codes: B60L 53/665 Methods related to measuring, billing or payment
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 50/10 using inductive coupling
• 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 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• 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 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: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

An electrical charging system configured to charge a battery includes a power transmitter, an energy coupling arrangement, an electrical signal shaping device including a controller, and an alignment means. The arrangement includes a first inductive coil disposed external to the vehicle and a second inductive coil attached with the vehicle. The alignment means communicates with the vehicle to ensure repeatable vehicle positioning so that the second inductive coil is positioned relative to the first inductive coil so that the second inductive coil receives the energy produced by the power transmitter wirelessly transmitted from the first inductive coil. The energy received by the second inductive coil is electrically shaped by the electrical signal shaping device and further transmitted through the electrical signal shaping device as controlled by the controller to charge the battery. Methods for transmitting energy through the electrical charging system to charge the battery are also presented.

Claims

1. An electrical charging system to electrically charge an energy storage device of a vehicle, comprising:

a power transmitter configured to provide energy;

an energy coupling arrangement having an off-vehicle inductive coil and an on-vehicle inductive coil, the off-vehicle coil being disposed external to the vehicle and in electrical communication with the power transmitter and the on-vehicle coil being disposed on the vehicle, the on-vehicle coil being configured to receive at least a portion of the energy wirelessly transmitted from the off-vehicle coil; and

an electrical signal shaping device in electrical communication with the on-vehicle coil to electrically shape a portion of said received energy and electrically transmit said electrically-shaped energy to electrically charge the energy storage device, and the electrical signal shaping device-includes a controller,

wherein electrical signal shaping device further includes a transfer switch in downstream electrical communication with the on-vehicle coil, wherein the energy storage device is in downstream electrical communication with the transfer switch, wherein an amplifier in the power transmitter is periodically activated by the electrical charging system to determine if the vehicle is in a distance range with the off-vehicle coil effective for the on-vehicle coil to receive energy wirelessly transmitted from the off-vehicle coil, wherein a data message is electrically transmitted from the power transmitter to the electrical signal shaping device and then further electrically transmitted to electronic devices in the vehicle to indicate to the electronic devices in the vehicle that electrical charging of the energy storage device by the electrical charging system is available, wherein the data message is acknowledged by the vehicular electronic devices to the electrical charging system, wherein the vehicular electronic devices determine that electrical charging system charging conditions to electrically charge the energy storage device are met, wherein an electrical charge request is transmitted from the vehicle to the power transmitter, wherein the electrical charge request is acknowledged by the vehicle to the electrical charging system, wherein a required charge voltage message is transmitted by the vehicle to the electrical charging system, wherein the required charge voltage message is acknowledged by the electrical charging system, whereby the electrical charging system adjusts a voltage of the electrical charging system to electrically charge the energy storage device, wherein the transfer switch is energized by the electrical charging system, wherein a ready to electrically charge data message is transmitted from the vehicular electronic devices to the electrical charging system, wherein the ready to electrically charge message is acknowledged by the electrical charging system to the vehicular electronic devices, and wherein the energy storage device is electrically charged by the electrical charging system.

2. The electrical charging system according to claim 1, wherein the power transmitter includes:

a housing enclosing a plurality of electrical components including at least a first portion, a second portion, and a third portion of electrical components in the plurality of electrical components;

an electrical output extending from the second portion and in electrical communication with the off-vehicle coil;

a DC power supply formed from the first portion of electrical components;

an amplifier formed from the second portion of electrical components, the amplifier further being in electrical communication with the DC power supply; and

a user interface formed from the third portion of electrical components, the user interface provides operating condition information of the electrical charging system to a human operator of the electrical charging system.

3. The electrical charging system according to claim 2, wherein the user interface has at least one visual element seen by eyes of the human operator.

4. The electrical charging system according to claim 2, wherein the user interface comprises at least one provision that allows a human operator of the electrical charging system to command the electrical charging system to perform at least one operation.

5. The electrical charging system according to claim 2, wherein the user interface includes at least one of:

(i) a light emitting diode (LED),

(ii) a LCD display,

(iii) a LED display, and

(iv) at least one push button.

6. The electrical charging system according to claim 2, wherein the plurality of electrical components includes a fourth portion of electrical components and the power transmitter further includes a wireless data communication section formed from the fourth portion of the plurality of electronic components, and the data communication section electrically wirelessly communicates with the controller disposed in the electrical signal shaping device.

7. A method to electrically charge an energy storage device in a vehicular electrical charging system, comprising the steps of:

providing the electrical charging system that includes a power transmitter, an energy coupling arrangement, at least one electrical signal shaping device that includes a controller, wherein the energy coupling arrangement includes an off-vehicle coil and an on-vehicle coil, the off-vehicle coil is in electrical communication with the power transmitter and the on-vehicle coil being disposed on the vehicle, and the electrical signal shaping device is in electrical communication with the on-vehicle coil;

periodically activating an amplifier in the power transmitter by the electrical charging system to determine if the vehicle is in a distance range with the off-vehicle coil effective for the on-vehicle coil to receive energy wirelessly transmitted from the off-vehicle coil;

electrically transmitting a data message from the power transmitter to the electrical signal shaping device that is further electrically transmitted to electronic devices in the vehicle to indicate to the electronic devices in the vehicle that electrical charging of the energy storage device by the electrical charging system is available;

acknowledging the data message by the vehicular electronic devices to the electrical charging system;

determining, by the vehicular electronic devices, that electrical charging system charging conditions to electrically charge the energy storage device are met;

transmitting an electrical charge request from the vehicle to the power transmitter;

acknowledging the electrical charge request by the vehicle to the electrical charging system;

transmitting a required charge voltage message by the vehicle to the electrical charging system;

acknowledging the required charge voltage message by the electrical charging system so that the electrical charging system adjusts a voltage of the electrical charging system to electrically charge the energy storage device;

energizing the transfer switch by the electrical charging system;

transmitting a ready to electrically charge data message from the vehicular electronic devices to the electrical charging system;

acknowledging the ready to electrically charge message by electrical charging system to the vehicular electronic devices; and

electrically charging the energy storage device by the electrical charging system.

8. The method according to claim 7, wherein the electrical charging system charging conditions include,

(i) the vehicle is not being electrically charged by a plug-in charger system,

(ii) the energy storage device requires electrical charging,

(iii) vehicle'"'"'s transmission is in a park position,

(iv) an ignition key of the vehicle is in an OFF position, and

(v) at least a portion of the vehicle'"'"'s power is de-energized.

9. The method according to claim 7, wherein when the energy storage device has a full state of electrical charge, and the method further includes the steps of:

electrically transmitting a charge complete data massage from the vehicular electrical devices to the electrical charging system;

acknowledging, by the electrical charging system, the charge complete data message;

de-energizing the amplifier of the power transmitter of the electrical charging system and the transfer switch of the electrical charging system by the electrical charging system; and

electrically transmitting a power off data message to the vehicular electronic devices by the electrical charging system.