Contactless battery system utilizing a bidirectional power converter

• US 10,637,296 B2
• Filed: 01/23/2018
• Issued: 04/28/2020
• 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): Aisaka, Bryce M
• Application Number:
  US15/878,393
• Publication Number:
  US 20180152042A1
• Time in Patent Office: 826 Days
• Field of Search: 320108
• 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 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. A first bidirectional power converter is employed in a sealed battery unit having no external electrical contacts. A second bidirectional power converter is employed in a corresponding cart bidirectional power converter assembly. The battery unit and the cart bidirectional power converter assembly cooperate to wirelessly transmit power from the battery unit to a load of the cart bidirectional power converter assembly and from a power source to the battery unit via the cart bidirectional power converter assembly.

Claims

1. A battery unit comprising:

a battery configured to selectively store direct current (DC) power and selectively provide DC power;

a coil;

a bidirectional power converter connected to the coil, the bidirectional power converter including a DC input terminal connected to the battery, and a DC output terminal connected to the battery wherein the bidirectional power converter is configured to selectively operate in

a transmit mode operable to provide power from the battery to the coil, and

a receive mode operable to receive power from the coil and provide power to the battery for storage via the DC output terminal;

a hall effect sensor configured to sense proximity of a magnet and provide a presence signal indicative of the proximity of the magnet; and

a microprocessor connected to the bidirectional power converter and the hall effect sensor, wherein the microprocessor is configured to communicate with a cart bidirectional power converter assembly,

wherein the microprocessor is further configured to, in response to the microprocessor communicating with the cart bidirectional power converter assembly,

set the bidirectional power converter to operate in the transmit mode, and

provide a transmission enable signal to the bidirectional power converter in response to receiving the presence signal from the hall effect sensor indicating the presence of the magnet, and

wherein, the microprocessor is further configured to, in response to the microprocessor communicating with the cart bidirectional power converter assembly, set the bidirectional power converter to operate in the receive mode.

2. The battery unit of claim 1, wherein the microprocessor being configured to communicate with the cart bidirectional power converter assembly comprises the microprocessor being configured to communicate with a microprocessor of the cart bidirectional power converter assembly via Bluetooth to determine in which mode to set the bidirectional power converter.

3. The battery unit of claim 1, wherein the bidirectional power converter further comprises a control logic configured to

receive a temperature sensing signal;

receive the transmission enable signal; and

provide a modulator enable signal as a function of the temperature sensing signal and the transmission enable signal.

4. The battery unit of claim 1, wherein:

the bidirectional power converter further comprises an alternating current (AC), terminal connected to the coil; and

the bidirectional power converter is further operable to provide AC power at the AC terminal in the transmit mode and provide DC power at the DC output terminal in the receive mode.

5. The battery unit of claim 4, wherein the bidirectional power converter further comprises an oscillator configured to provide a drive signal at a base frequency when the bidirectional power converter is operating in the transmit mode.

6. The battery unit of claim 5, wherein the bidirectional power converter further comprises:

an amplifier configured to receive power from a power source via the DC input terminal and provide an AC output signal to the AC terminal 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 at the bidirectional power converter and provide the hysteretic control signal to the modulator as a function of the transmitted control signal when the bidirectional power converter is operating in the transmit mode; and

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

7. The battery unit of claim 6, wherein:

the amplifier comprises a full bridge amplifier; and

the modulator comprises an amplitude shift keyed modulator.

8. The battery unit of claim 6, wherein 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 magnetic field.

9. The battery unit of claim 4, wherein the bidirectional power converter further comprises:

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

a receive relay configured to enable the rectifier to provide the DC output to the DC output terminal when the bidirectional power converter is operating in the receive mode and prevent the rectifier from providing the DC output to the DC output terminal when the bidirectional power converter is operating in the transmit 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.

10. The battery unit of claim 9, wherein the rectifier comprises a full wave rectifier.

11. The battery unit of claim 9, wherein the hysteretic control circuit comprises:

a hysteretic controller configured to provide a logic signal, wherein the logic signal comprises a first binary value when a voltage of the DC output is less than a predetermined threshold and the logic signal further comprises 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.