Wireless battery charger with wireless control system

• US 10,186,894 B2
• Filed: 05/08/2017
• Issued: 01/22/2019
• Est. Priority Date: 04/30/2015
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG
• Original Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Inventors: Ely, Jeffrey A., Simopoulos, Gregory N.
• Primary Examiner(s): Dunn, Drew A
• Assistant Examiner(s): Thapa, Sailesh
• Application Number:
  US15/588,767
• Publication Number:
  US 20170244273A1
• Time in Patent Office: 624 Days
• Field of Search: 320108
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: H02J 50/10 using inductive coupling
• 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 7/00034 Charger exchanging data with an electronic device, i.e. telephone, whose internal battery is under charge
• 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 90/14 Plug-in electric vehicles

Abstract

A wireless electrical charging system and a method of operating same wherein operating parameters from a remote portion of the system are wirelessly transmitted to a system controller controlling the output voltage of an alternating power supply. The system controller executes an adaptive model control algorithm that allows the system controller to update the output voltage at a greater rate than the transmission rate of the operating parameters from the remote portion of the system.

Claims

1. An electrical charging system configured to wirelessly charge an energy storage device, comprising:

an electrical power supply configured to source electrical power having an alternating output current and an alternating output voltage;

an output current sensor configured to determine an output current value (i_o) based on an output current and an output voltage sensor configured to determine an output voltage value (v_o) based on an output voltage;

a source coil in electrical communication with the electrical power supply and configured to generate an alternating magnetic field;

a capture coil configured to be magnetically coupled to said source coil, thereby inducing the capture coil to capture the electrical power;

a rectifier electrically coupled to the capture coil and the energy storage device and configured to provide captured electrical power having a direct voltage and a direct current;

a battery charging controller configured to determine a current command value (i_c);

a direct current sensor configured to determine a direct current value (i_d) based on the direct current and a direct voltage sensor configured to determine a direct voltage value (v_d) based on the direct voltage;

a transmitter configured to transmit a sampled current command value (i_cs), a sampled direct voltage value (v_ds), and a sampled direct current value (i_ds) at a transmission rate, wherein the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and direct current value (i_ds) are sampled from the current command value (i_c), direct voltage value (v_d), and the direct current value (i_d) respectively;

a receiver configured to wirelessly receive the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) from the transmitter; and

a system controller in electrical communication with the receiver and the electrical power supply and configured to determine a voltage command value (v_c) based on the output current value (i_o), the output voltage value (v_o), the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds), wherein the electrical power supply is configured to adjust the output voltage value (v_o) based on the voltage command value (v_c), and wherein a rate at which the voltage command value (v_c) is determined by the system controller is greater than the transmission rate of the transmitter, wherein the system controller determines the voltage command value (v_c) based on a difference between the sampled current command value (i_cs) and a predicted current value (i_p) according to the Laplace transform formula;

v_c=(i_cs−

i_p)*(K_P2+K_I2/S), wherein values of K_P1 and K_P2 are proportional constants and values of K_I1 and K_I2 are integral constants, wherein the predicted current value (i_p) is determined according to an adaptive model formula;

i_p=((K₁*v_o*i_o)−

K₀)/v_ds, wherein a rate of change of the value of K₀ increases and a rate of change of the value of K₁ decreases as an output power (p_o=i_o*v_o) increases.

2. The electrical charging system according to claim 1, wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ is fixed when the output power is in a first power range, wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ vary when the output power is in a second power range having greater output power than the first power range, and wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ is fixed when the output power is in a third power range having greater output power than the second power range.

3. The electrical charging system according to claim 2, wherein the value of K₀ is fixed when the output power is in the third power range and wherein the rate of change of the value of K₀ is fixed when the output power is in the first power range.

4. The electrical charging system according to claim 3, wherein the value of K₁ is fixed when the output power is in the first power range and wherein the rate of change of the value of K₁ is fixed when the output power is in the third power range.

5. The electrical charging system according to claim 4, wherein the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) are transmitted periodically by the transmitter at the transmission rate.

6. The electrical charging system according to claim 5, wherein the predicted current value (i_p) is determined by the system controller at a rate greater than the transmission rate at which the sampled current command value (i_cs) is transmitted periodically by the transmitter.

7. The electrical charging system according to claim 6, wherein transmission of the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) are time delayed by the transmitter.

8. A method of operating an electrical charging system configured to wirelessly charge an energy storage device having an electrical power supply configured to source electrical power having an alternating output current and an alternating output voltage at a desired frequency, a source coil in electrical communication with the electrical power supply and configured to generate an alternating magnetic field, a capture coil configured to be magnetically coupled to said source coil, thereby inducing the capture coil to capture the electrical power, a rectifier electrically coupled to the capture coil and the energy storage device and configured to provide captured electrical power having a direct voltage and a direct current, and a system controller in electrical communication with the electrical power supply and configured to adjust the alternating output voltage, said method comprising the steps of:

providing an output current sensor configured to determine an output current value (i_o) based on an output current and providing an output voltage sensor configured to determine an output voltage value (v_o) based on an output voltage;

providing a battery charging controller configured to determine a current command value (i_c);

providing a direct current sensor configured to determine a direct current value (i_d) based on the direct current and providing a direct voltage sensor configured to determine a direct voltage value (v_d) based on the direct voltage;

sampling values of the current command value (i_c), direct voltage value (v_d), and the direct current value (i_d);

providing a transmitter configured to transmit a sampled current command value (i_cs), a sampled direct voltage value (v_ds), and a sampled direct current value (i_ds) at a transmission rate and providing a receiver configured to wirelessly receive the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) from the transmitter;

transmitting the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) from the transmitter to the receiver;

determining a voltage command value (v_c), via the system controller, based on the output current value (i₀), the output voltage value (v_o), the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds), wherein a rate at which the voltage command value (v_c) is determined by the system controller is greater than the transmission rate of the transmitter; and

adjusting the output voltage value (v_o) of the electrical power supply based on the voltage command value (v_c), wherein the voltage command value (v_c) is determined, via the system controller, based on a difference between the sampled current command value (i_cs) and a predicted current value (i_p) according to the Laplace transform formula;

v_c=(i_cs−

i_p)*(K_P2+K_I2/S), wherein values of K_P1 and K_P2 are proportional constants and values of K_I1 and K_I2 are integral constants, wherein the predicted current value (i_p) is determined, via the system controller, according to an adaptive model formula;

i_p=((K₁*v_o*i_o)−

K₀)/v_ds, wherein a rate of change of the value of K₀ increases and a rate of change of the value of K₁ decreases as an output power (p_o=i_o*v_o) increases.

9. The method according to claim 8, wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ is fixed when the output power is in a first power range, wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ vary when the output power is in a second power range having greater output power than the first power range, and wherein the rate of change of the value of K₀ and the rate of change of the value of K₁ is fixed when the output power is in a third power range having greater output power than the second power range.

10. The method according to claim 9, wherein the value of K₀ is fixed when the output power is in the third power range and wherein the rate of change of the value of K₀ is fixed when the output power is in the first power range.

11. The method according to claim 10, wherein the value of K₁ is fixed when the output power is in the first power range and wherein the rate of change of the value of K₁ is fixed when the output power is in the third power range.

12. The method according to claim 11, wherein the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) are transmitted periodically by the transmitter at the transmission rate.

13. The method according to claim 12, wherein the predicted current value (i_p) is determined by the system controller at a rate greater than the transmission rate at which the sampled current command value (i_cs) is transmitted periodically by the transmitter.

14. The method according to claim 13, wherein transmission of the sampled current command value (i_cs), the sampled direct voltage value (v_ds), and the sampled direct current value (i_ds) are time delayed by the transmitter.