Checking alignment of inductive charge pads in motion

• US 10,284,028 B2
• Filed: 05/30/2017
• Issued: 05/07/2019
• Est. Priority Date: 05/27/2016
• Status: Active Grant

• Current Assignee: Wireless Advanced Vehicle Electrification, Inc.
• Original Assignee: Wireless Advanced Vehicle Electrification, Inc.
• Inventors: Lethellier, Patrice, Ball, Steve, Harper, Marcellus, Masquelier, Michael, Wu, Hunter
• Primary Examiner(s): Lin, Sun
• Application Number:
  US15/608,835
• Publication Number:
  US 20170346348A1
• Time in Patent Office: 707 Days
• Field of Search: 320108
• 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 53/38 specially adapted for charging by inductive energy transfer
• CPC Class Codes: G01B 2210/58 Wireless transmission of information between a sensor or probe and a control or evaluation unit
• CPC Class Codes: G01B 7/31 for testing the alignment of axes
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• 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 7/00034 Charger exchanging data with an electronic device, i.e. telephone, whose internal battery is under charge
• CPC Class Codes: H02J 7/04 Regulation of charging current or 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

An approach module determines that a wireless power transfer (WPT) secondary pad on a vehicle approaching a WPT primary pad is within an approach distance threshold from the WPT primary pad. A pulse module generates an electrical alignment pulse in the WPT primary pad or WPT secondary pad in response to determining that the WPT secondary pad is within the approach distance. A measurement module determines an amount of magnetic coupling between the WPT primary pad and the WPT secondary pad, and a feedback module that provides an alignment signal to a driver of the vehicle. The alignment signal represents magnetic coupling. The pulse module continues to provide electrical alignment pulses, the measurement module continues to determine an amount of magnetic coupling in response to the electrical alignment pulses, and the feedback module continues to provide alignment signals indicative of an amount of magnetic coupling as the vehicle moves in relation to the WPT primary pad.

Claims

1. An apparatus comprising:

an approach module that determines that a wireless power transfer (“

WPT”

) secondary pad on a vehicle approaching a WPT primary pad is within an approach distance threshold from the WPT primary pad;

a pulse module that generates an electrical alignment pulse in one of the WPT primary pad and the WPT secondary pad in response to the approach module determining that the WPT secondary pad is within the approach distance threshold;

a measurement module that determines an amount of magnetic coupling between the WPT primary pad and the WPT secondary pad; and

a feedback module that provides an alignment signal to a driver of the vehicle, the alignment signal indicative of the amount of magnetic coupling,

wherein the pulse module continues to provide electrical alignment pulses, the measurement module continues to determine an amount of magnetic coupling in response to the electrical alignment pulses, and the feedback module continues to provide the alignment signal to the driver indicative of an amount of the magnetic coupling as the vehicle moves in relation to the WPT primary pad.

2. The apparatus of claim 1, wherein the alignment signal is one or more of a visual indicator on an electronic display and an audio signal.

3. The apparatus of claim 1, wherein the feedback module further comprises a lower limit module that provides one or more of a visual indication that indicated the amount of magnetic coupling is above a lower coupling limit and an audio signal comprising a distinct sound indicative of the amount of magnetic coupling being above the lower coupling limit.

4. The apparatus of claim 3, wherein the feedback module further comprises an upper limit module that provides one or more of a visual indication that indicates the amount of magnetic coupling is below an upper coupling limit and an audio signal comprising a distinct sound indicative of the amount of magnetic coupling being below the upper coupling limit.

5. The apparatus of claim 4, wherein the feedback module dynamically adjusts the lower coupling limit and the upper coupling limit is based on one or more of a battery charge level of a battery on the vehicle, a load level of the vehicle, and one or more operating limits of a wireless power transfer system comprising the WPT primary pad and WPT the secondary pad.

6. The apparatus of claim 1, wherein:

the pulse module generates the electrical alignment pulse in the WPT primary pad; and

the measurement module measures a secondary voltage on a circuit coupled to the WPT secondary pad and a primary current in the WPT primary pad, wherein the amount of magnetic coupling is proportional to a ratio of the secondary voltage and the primary current.

7. The apparatus of claim 1, wherein:

the pulse module generates the electrical alignment pulse in the WPT secondary pad; and

the measurement module measures a primary voltage on a circuit coupled to the WPT primary pad and a secondary current in the WPT secondary pad, wherein the amount of magnetic coupling is proportional to a ratio of the primary voltage and the secondary current.

8. The apparatus of claim 1, wherein the approach module determines if the WPT secondary pad is within the approach distance threshold from the WPT primary pad by one of:

generating a low power pulse on the WPT secondary pad and determining if a signal is present on the WPT primary pad is above an approach signal threshold; and

generating a low power pulse on the WPT primary pad and determining if a signal is present on the WPT secondary pad is above an approach signal threshold, wherein the low power pulse has a power level lower than a power level for wireless power charging from the WPT primary pad to the WPT secondary pad.

9. The apparatus of claim 8, wherein the approach module generates the low power pulse in response to one or more of:

a radio contact between the vehicle and one or more components of a first stage comprising the WPT primary pad;

a radio signal strength between the vehicle and one or more components of the first stage comprising the WPT primary pad being above a radio signal threshold;

a speed of the vehicle being below a speed threshold; and

a global positioning satellite (“

GPS”

) signal indicating that the WPT secondary pad is within a GPS distance limit from the WPT primary pad.

10. The apparatus of claim 8, wherein the approach module performs one or more of:

automatically generates the low power pulse;

manually generates the low power pulse in response to an input from an operator of the vehicle; and

manually generates the low power pulse in response to an input from an operator of the vehicle and one or more safety conditions being met.

11. The apparatus of claim 8, wherein the approach module generates the low power pulse from the WPT secondary pad and the pulse module generates the electrical alignment pulse on the WPT primary pad.

12. The apparatus of claim 1, wherein the pulse module generates the electrical alignment pulse prior to the WPT primary pad transmitting power to the WPT secondary pad during a wireless power transfer operation to provide a power to a load of the vehicle.

13. The apparatus of claim 1, wherein the approach distance threshold is set based on magnetic field safety limits.

14. The apparatus of claim 1, further comprising a kneeling module that lowers a portion of the vehicle, wherein the feedback module provides the alignment signal to the driver of the vehicle in response to one or more of

the vehicle approaching the WPT primary pad;

and

the kneeling module lowering the portion of the vehicle.

15. The apparatus of claim 1, wherein the electrical alignment pulse comprises one of:

a constant amount of energy for a period of time followed by a time with no pulse, wherein the pulse module provides a plurality of alignment pulses as the vehicle moves in relation to the WPT primary pad; and

a ramped alignment pulse, the ramped alignment pulse generated by increasing an amount of energy over a period of time, wherein the pulse module provides a plurality of ramped alignment pulses as the vehicle moves in relation to the WPT primary pad.

16. A system comprising:

a first stage of a wireless power transfer (“

WPT”

) system, the first stage comprising a WPT primary pad and one or more of a resonant converter and an alternating current (“

AC”

) to direct current (“

DC”

) converter, the first stage configured to wirelessly transmit power to a second stage on a vehicle, the second stage comprising a WPT secondary pad and a secondary circuit that receives power from the WPT primary pad and transfers power to a load of the vehicle;

an approach module that determines that a WPT secondary pad on a vehicle approaching the WPT primary pad is within an approach distance threshold from the WPT primary pad;

a pulse module that generates an electrical alignment pulse in one of the WPT primary pad and the WPT secondary pad in response to the approach module determining that the WPT secondary pad is within the approach distance;

a measurement module that determines an amount of magnetic coupling between the WPT primary pad and the WPT secondary pad; and

a feedback module that provides an alignment signal to a driver of the vehicle, the alignment signal indicative of the amount of magnetic coupling,

wherein the pulse module continues to provide electrical alignment pulses, the measurement module continues to determine an amount of magnetic coupling in response to the electrical alignment pulses, and the feedback module continues to provide alignment signals to the driver indicative of an amount of magnetic coupling as the vehicle moves in relation to the WPT primary pad.

17. The system of claim 16, further comprising one or more of the second stage, the vehicle and the load.

18. A method comprising:

determining that a wireless power transfer (“

WPT”

) secondary pad on a vehicle approaching a WPT primary pad is within an approach distance threshold from the WPT primary pad;

generating an electrical alignment pulse in one of the WPT primary pad and the WPT secondary pad in response to determining that the WPT secondary pad is within the approach distance threshold;

determining an amount of magnetic coupling between the WPT primary pad and the WPT secondary pad; and

providing an alignment signal to a driver of the vehicle, the alignment signal indicative of the amount of magnetic coupling,

wherein the method continues to provide electrical alignment pulses, continues to determine an amount of magnetic coupling in response to each of the electrical alignment pulses, and continues to provide alignment signals to the driver indicative of an amount of magnetic coupling as the vehicle moves in relation to the WPT primary pad.

19. The method of claim 18, further comprising providing one or more of a visual indication that indicates the amount of magnetic coupling is above a lower coupling limit and an audio signal comprising a distinct sound indicative of the amount of magnetic coupling being above the lower coupling limit, and further comprising providing one or more of a visual indication that indicates the amount of magnetic coupling is below an upper coupling limit and an audio signal comprising a distinct sound indicative of the amount of magnetic coupling being below the upper coupling limit.

20. The method of claim 18, wherein the determining if the WPT secondary pad is within the approach distance threshold from the WPT primary pad comprises one of:

generating a low power pulse on the WPT secondary pad and determining if a signal is present on the WPT primary pad is above an approach signal threshold; and

generating a low power pulse on the WPT primary pad and determining if a signal is present on the WPT secondary pad is above an approach signal threshold, wherein the low power pulse has a power level lower than a power level for wireless power charging from the WPT primary pad to the WPT secondary pad.