Power-factor-corrected single-stage inductive charger

• US 6,160,374 A
• Filed: 08/02/1999
• Issued: 12/12/2000
• Est. Priority Date: 08/02/1999
• Status: Expired due to Term

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Egan, Michael G., Hayes, John G.
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US09/364,997
• Time in Patent Office: 498 Days
• Field of Search: 320/108, 320/137, 320/140, 320/143, 336/DIG. 2
• US Class Current: 320/108
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• 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: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02M 1/4258 using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage H02M1/4241 takes precedence
• 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

Abstract

The present invention comprises a power-factor-corrected, single-stage inductive charger that may be used to charge a load, such as batteries of an electric vehicle. The inductive charger system is a single stage inductive charger compatible with the Society of Automotive Engineers inductive charging standard SAE J-1773. The single stage power processing provided by the inductive charger system includes both power factor correction and output power regulation using a relatively low parts count. The inductive charger system is fully soft switched over the line voltage and power range, resulting in high efficiency. The inductive charger system uses the current source operation of a series-parallel resonant converter feeding the SAE J- 1773 interface to provide voltage gain for power factor correction over the full AC line cycle. The operating frequency of the converter is modulated around the current-source frequency to regulate the output power from zero to full load.

Claims

1. An inductive charger system comprising:

an AC line rectifier;

a filter capacitor coupled across the line rectifier;

an inverter coupled to the line rectifier and the filter capacitor;

a series resonant tank circuit coupled to the inverter;

a charge coupler and inductive inlet comprising a transformer and a parallel resonant tank circuit for coupling energy to a load;

a controller for regulating power supplied to the load by increasing the operating frequency of the system to reduce output current for a given voltage;

wherein the parallel resonant tank circuit comprises a parallel inductance and a parallel capacitor, and

wherein the parallel inductance and parallel filter capacitor are disposed in the inductive inlet.

2. The system recited in claim 1 wherein the filter capacitor comprises a high frequency non-electrolytic filter capacitor.

3. The system recited in claim 2 wherein the inverter comprises a MOSFET-based fill-bridge inverter.

4. The system recited in claim 1 wherein the inverter comprises a MOSFET-based half-bridge inverter.

5. The system recited in claim 1 wherein the load comprises batteries of an electric vehicle.

6. The system recited in claim 3 wherein the full bridge inverter includes a plurality of controlled switches, their intrinsic antiparallel diodes, and snubber capacitors to facilitate zero-voltage-switching.

7. The system recited in claim 6 wherein the first and third switches are gated together in a complementary fashion to second and fourth switches.

8. The system recited in claim 1 wherein the controller comprises:

an attenuator for attenuating the rectified AC line voltage to provide a reference line voltage signal;

a current amplifier for sensing the rectified AC line current and for amplifying the sensed signal to provide a feedback line current signal;

a multiplier for multiplying the reference line voltage signal by the feedback line current signal to generate an instantaneous feedback power signal;

an averaging circuit for averaging the instantaneous feedback power signal to provide an average feedback power signal;

a power-to-voltage scaling multiplier for multiplying the average power error signal by a power-to-voltage scaling factor to generate a line voltage scaling factor a multiplier for multiplying the reference line voltage signal by the line voltage scaling factor to generate a reference line current signal;

an adder for subtracting the feedback line current signal from the reference line current signal to generate a current error signal;

an error amplifier for amplifying the current error signal; and

a voltage to frequency converter for converting the current error signal into gate drive signals for the switches of the inverter.

9. An inductive charger system for a vehicle comprising:

an AC line rectifier;

a filter capacitor coupled across the line rectifier;

an inverter coupled to the line rectifier and the filter capacitor;

a series resonant tank circuit coupled to the inverter;

a charge coupler and inductive inlet for coupling power to the vehicle comprising a transformer and a parallel resonant tank circuit; and

a controller for regulating power supplied to the vehicle by increasing the operating frequency of the system to reduce output current for a given voltage.

10. The inductive charger system of claim 9, wherein the charge coupler comprises a plug insertable into the inductive inlet.

11. An inductive charger system for a vehicle comprising:

a first charging circuit comprising;

an AC line rectifier;

a filter capacitor coupled across the line rectifier;

an inverter coupled to the line rectifier and the filter capacitor;

a series resonant tank circuit coupled to the inverter;

a second charging circuit located in the vehicle that electromagnetically couples to said first charging circuit to transfer electrical energy from said first charging circuit to said second charging circuit using a charge coupler and inductive inlet comprising a transformer and a parallel resonant tank circuit; and

a controller for regulating power supplied to the load by increasing the operating frequency of the system to reduce output current for a given voltage.

12. The inductive charger system of claim 11, wherein the first charging circuit and second charging circuit are adapted to be physically decoupled.