Patent Application
20240235269
The invention is concerned with a method for operating an inverter circuit in a wireless power transmission device. The inverter circuit comprises at least one half-bridge with two switching units that each have a parasitic capacitance that needs to be considered for achieving the so-called zero-volt switching or zero-voltage switching (ZVS). The invention is also concerned with a wireless power transmission device that is designed to be operated according to the inventive method.
Wireless, inductive power transmission systems have huge advantages over cable connected systems. Due to technological advancements, such wireless charging systems for mobile batteries gain more and more attention. For example, charging stations for mobile batteries of mobile robots or forklift trucks or floor conveyors or electric vehicles can be charged using such inductive power transmission systems without the need to connect a charging cable.
In general, inductive power transmission systems consist of a stationary and a mobile side. In this description, the stationary side is also termed “wireless power transmission device” and “primary side”. The stationary side has a switched mode electronic inverter circuit and—connected to this inverter circuit as a load—a resonant circuit consisting of at least one capacitor and a transmission coil (sending coil). On the mobile side, a voltage and current are induced in a receiving coil and a belonging resonant circuit. Further on the mobile side, a passive or active rectifier feeds directly a battery or a mobile energy system which consists of several loads (e.g. DC/DC-converter) and energy storage devices (e.g. Batteries, Supercaps, Ultracaps).
The cables leading from the inverter circuit to the transmission coils systems are switched at the power transfer frequency, carry significant voltage and power. On the primary side a resonant commutation of the load current is desired in the inverter circuit in order to reduce switching losses and EMI (electro-magnetic interference). To keep EMI and losses low, resonant power transfer is used. However, some of the key resonant components vary with coil alignment (transmission and receiving coils), spacing of coils, output voltage and current. Keeping the operating power transfer frequency within a small range becomes very difficult. It has been found that failing to operate the resonant arrangement comprising the primary side and the secondary side may lead to increased heat development in the inverter circuit and also to increased EMI when the power transfer frequency does not match the resonant frequency of the resonant arrangement.
Document EP 3 599 700 B1 discloses a wireless power transmission system to which the invention may be applied.
Documents EP 3 451 493 A1 and RU 2 553 660 C2 each disclose inverter circuits that provide zero volt switching capabilities by providing an additional support circuit.
It is an objective of the present invention to reduce power losses and EMI in a primary side wireless, inductive power transmission device.
The objective is accomplished by the subject matter of the independent claims. Advantageous developments with convenient and non-trivial further embodiments of the invention are specified in the following description, the dependent claims and the figures.
According to a first aspect the invention provides a method for operating an inverter circuit in a wireless power transmission device. The method is based on the following known design of the wireless, inductive power transmission device, i.e. the stationary or primary side of a wireless power transmission system. The inverter circuit comprises at least one half-bridge with two switching units that each have a parasitic capacitance and that each comprise a freewheeling element. Each switching unit may comprise at least one switching element, In particular, such a switching element may be provided in the form of a transistor or a thyristor. In the case of several such switching elements, some or all of these switching elements may be connected in parallel (for carrying more electric current). Some or all of these switching elements may be connected in series (for switching higher voltages). In the respective half-bridge the first switching unit links a plus terminal or plus potential of a DC source (DC—direct current) to a half-bridge node or output node of the half-bridge. The second switching unit links this half-bridge 10 node to a minus terminal or minus potential of the DC source. In other words, in each half-bridge the switching units are connected in series and they interconnect the plus potential and the minus potential of the DC source. Such a DC source can be, e.g., a DC link with a DC link capacitor and/or the output of a rectifier. The electric connection point between the two switching units inside the half-bridge is the output node or half-bridge node of that half-bridge.
To this half-bridge node a resonant circuit for the wireless power transmission is connected as a load. The resonant circuit comprises one or more than one transmission coil (sending coil) and at least one capacitive element, like is known from 20 the prior art. One half-bridge node may be electrically connected to a respective electrical contact or connector of the resonant circuit. If only one half-bridge is provided, a second electrical contact or connector of the resonant circuit may be connected to a neutral potential (for completing the electric circuit). If two half-bridges are provided, the second electrical contact or connector of the resonant circuit may be connected to the half-bridge node of the second half-bridge, such that the two half-bridges may be operated as a full H-bridge. By means of the at least one half-bridge, an AC current may be evoked in the resonant circuit. To this end, the voltage that the load receives from the inverter circuit at the respective half-bridge node is repeatedly switched from a first voltage value to a second voltage value and back to the first voltage value.
For providing such a switched voltage at the half-bridge node of each half-bridge, a switching cycle is repeatedly performed at a power transfer frequency, wherein the switching cycle comprises that in each half-bridge a control circuit alternatingly connects the half-bridge node to the plus potential in one half-cycle and then to the minus potential in the other half-cycle by setting the corresponding switching unit into an on state while keeping the respective other switching unit in an off state. In the on state the respective switching unit has its minimum electric resistance (switching unit is “closed”) and the half-bridge node is therefore electrically connected to the respective potential of the DC source (plus potential or minus potential). As the other switching unit is in the off state it blocks any electric current such that no short circuit occurs (switching unit is “open”). The switching cycle may comprise a positive half-cycle (connection to plus potential) and a negative half-cycle (connection to minus potential). The duration of a single switching cycle is the inverse value of the power transfer frequency. If two half-bridges are used, their half-cycles are phase-shifted by 180°, as is known from the prior art for operating an H-bridge.
For alternating between the half-cycles, a transient phase is performed. Synonyms for “transient phase” are “deadtime phase” and “commutation phase” or “shifting phase”.
A dead time between the “opening” of the currently conductive switching unit (switching from the on state into the off state) and the “closing” of the currently blocking switching unit (switching from the off state into the on state) is needed. This prevents any short circuiting that may otherwise occur if both switching units in the respective half-bridge are switched at the same time. Accordingly, the transient phase comprises that the switching unit that is currently in the on state and provides an electric load current to the load is set into the off state. As now both switching units are in the off state (all switching elements, e.g. transistors, are non-conductive) this commutates the load current to the freewheeling element of the other switching unit (the one that has been in the off state for the now ending half-cycle). Note that the commutated load current is not driven by the DC source any more, but rather by the resonant circuit of the load.
The invention is based on the insight, that this commutated load current is needed for a zero-voltage switching at the end of the transient phase, as the parasitic capacitances of the switching units are charged and/or discharged by the commutated load current and by this the electric potential of the half-bridge node is shifted from the respective current potential (DC source plus potential or minus potential) to which it had been connected to during the last half-cycle, to the respective other potential to which it shall be connected to in the following half-cycle. This describes two cases: If in the current half-cycle (before the transient phase), the half-bridge node has been connected to the plus potential of the DC source, it is disconnected from that plus potential in the transient phase and due to the change in the charging state of the parasitic capacitances the electric potential of the half-bridge node is shifted towards the minus potential. Likewise, if in the current half-cycle, the half-bridge node has been connected to the minus potential of the DC source, the electric potential of the half-bridge node is shifted towards the plus potential.
Ideally, at the end of the transient phase, the electric potential of the half-bridge node should be shifted to the respective other potential of the DC source as close as possible, because the transient phase is finished by switching of the other switching unit into the on state, which should ideally be a zero-voltage switching, ZVS, i.e. the electric voltage should have an absolute value of zero or at most the electric voltage of the forward voltage of the at least one freewheeling element. For example, at the end of the transient phase, the absolute value of the voltage across the switching unit that is to be switched into the on state is less than 3 volts, preferably less than 2 volts. In general, absolute value the potential difference or voltage between the half-bridge node and the DC source potential that it will be connected to at the end of the transient phase, should be minimized.
In order to ensure this electric state of the half-bridge node at the end of each transient phase, an additional support circuit is connected in parallel to the load, wherein the support circuit comprises at least one energy storing element that is charged with energy by a charging current during the respective half-cycle and in the respective transient phase the support circuit drives a support current using the stored energy from its at least one energy storing element. The support current adds to the commutated load current in the inverter circuit and it has been found that this support current contributes to the charging and/or discharging of the parasitic capacitances of the switching units and by this supports shifting the potential of the half-bridge node.
The invention provides the advantage that even in the case that the resonant circuit or the resonant arrangement (comprising the resonant circuit of the primary side and the receiving resonant circuit of the mobile side) do not comprise enough energy to fully shift the electric potential of the half-bridge node for achieving a zero-voltage switching, the missing or additional energy (for charging and/or discharging the parasitic capacitances) is provided by the support circuit such that during the transient phase by driving the support current the electric energy for charging and/or discharging the parasitic capacitances is available. Thus, even if the resonant frequency of the resonant circuit or of the resonant arrangement as a whole is detuned or different with regard to the power transfer frequency, by providing the additional support circuit, zero-voltage switching can be supported. Thus, the switching units can be switched at minimum or at least lowered absolute potential difference or minimum voltage across a switching unit at the end of the respective transient phase. This reduces the losses and/or EMI in the inverter circuit.
It is noted here that the current through the switching circuit acts as the charging current in each half-cycle and as the support current during the transient phase. In general, the current through the support circuit is denoted here as additional current as it adds to the load current from the point of view of the inverter circuit.
The invention also comprises embodiments that provide features which afford additional technical advantages.
One embodiment comprises that two half-bridges are provided that each comprise a respective output node or half-bridge node. The two half-bridges are operated as an H-bridge for providing the switched voltage between their two half-bridge nodes, wherein the load and the support circuit are connected to the two half-bridge nodes. The two half-bridges may be operated inversely phased, i.e. at a phase shift of 180°. Thus, during the half-cycles, one half-bridge node is connected to the plus potential and the other half-bridge node is connected to the minus potential. This increases the absolute value of the voltage that is provided between the two half-bridge nodes for driving the load current in the resonant circuit. Each half-bridge node may be connected to a respective connector of the load and a respective connector of the support circuit.
One embodiment comprises that a DC current through the support circuit is blocked by at least one DC-blocking capacitor of the support circuit. The at least one DC-blocking capacitor may be provided in series to the at least one energy storage element. Thus, the charging current in the support circuit may charge or load the respective energy storage element with energy while at the same time a DC-component of the charging current through the support circuit is blocked by the at least one DC-blocking capacitor. This ensures that by the support circuit no DC short circuit for a common-mode component of the electric current flowing between the half-bridge nodes is caused or generated. A suitable capacity of a DC-blocking capacitor may be in the range of 50 nF to 400 nF.
One embodiment comprises that a fundamental component of the current through the support circuit (i.e. the additional current) is out of phase with regard to the load current. By choosing a support circuit with such a resonant behavior, it is possible to tune the support circuit with regard to the resonant behavior of the resonant circuit or load such that the fundamental component can be cancelled. This allows to suppress not only a DC-component but also the fundamental component. A suitable resonant behavior of the support circuit may be achieved on the basis of an LC-circuit (L—inductor, C—capacitor).
One embodiment comprises that high frequency, HF, signal components of the load current with a frequency of at least twice the power transfer frequency is lead to a ground potential by at least one Y-capacitor of the support circuit. This further reduces EMI by providing a low impedance for the high frequency signal components with regard to the ground potential. For choosing the correct Y-capacitor, the possible values for the power transfer frequency can be determined based on the design of the inverter circuit and/or the control circuit and then a suitable value for the respective Y-capacitor can be chosen on the basis of the formula for the capacitive reactance and/or the formula for calculating the resistance of an RC-circuit for a high-pass filter as known from the prior art. Preferably, the at least one Y-capacitor provides a high-pass filter with a cutoff frequency of said value in the range of 1.5 times the power transfer frequency to 3 times or 5 times the power transfer frequency. A Y-capacitor can have a value in a range from 47 pf to 10 nF, e.g. 4.7 nF.
One embodiment comprises that the power transfer frequency is in a range from 20 kHz to 150 KHz.
According to a second aspect the invention provides the already mentioned wireless power transmission device for an inductive electric power transmission. As has been explained, the wireless power transmission device can be used as the stationary or primary side of a wireless power transmission system that additionally may comprise the receiving side or mobile side. A receiving resonant circuit comprising a receiving coil may be used here as isknown from the prior art.
The power transmission device comprises the following components. One component is the resonant circuit for emitting the power to a receiving coil (by generating a time-varying magnetic field). The resonant circuit comprises one or more than one transmission coil and at least one capacitive element. The resonant circuit can be designed, e.g., as a coil with at least one integrated capacitor in the middle of the winding on both the primary and secondary side.
One further component is the inverter circuit with the at least one half-bridge node to which the resonant circuit is connected for receiving both the switched voltage and the load current (for generating the time varying magnetic field). The inverter circuit comprises at least one half-bridge with two switching units that each comprise a freewheeling element, wherein the first switching unit links a plus potential of a DC source to one half-bridge node and the second switching unit links the same half-bridge node to a minus potential of the DC source. Preferably, the inverter circuit comprises an H-bridge with two half-bridges resulting in two half-bridge nodes. It is noted here that the term “link” means that the respective switching unit is soldered or otherwise provided as a linking element between the half-bridge node and the respective electric terminal or potential of the DC source. Only when the respective switching unit is in the on state or when a current flows through the freewheeling element, there also is an electric connection between the half-bridge node and the respective potential. When the switching unit is in the off state and not freewheeling current is flowing, the at least one switching element, e.g. at least one transistor, blocks a current through the switching unit and thus no electric connection is provided.
One further component is the control circuit for controlling the switching units of the at least one half-bridge (for generating the switched voltage). The control circuit is designed to repeatedly perform a switching cycle at a power transfer frequency, wherein each switching cycle comprises two half-cycles that are separated by a respective transient phase (deadtime phase or commutation phase) where both the switching units are set to an off state and the current inside the inverter circuit commutates to at least one freewheeling element. The control circuit can be based, for example, on at least one microprocessor and/or at least one microcontroller and/or at least one ASIC (Application Specific Integrated Circuit) and/or on a circuitry of logic modules and/or an analogue multi-vibrator circuit. It is noted here that each half-cycle does not correspond to exactly half the duration of a full switching cycle as the duration of the two transient phases that are also part of each switching cycle need to be subtracted. As the duration of a half-cycle is at least 5 times (preferably at least 10 times) longer than the duration of the transient phase, the duration of the transient phase has been neglected and the term “half-cycle” was chosen here. An alternative term for “half-cycle” may be “on-cycle” as switching units are in the on state.
Each switching cycle comprises a succession of a transient phase, a positive half-cycle, another transient phase and a negative half-cycle. The choice of the value of the power transfer frequency can be made adaptive according to a known procedure that may be applied for matching the power transfer frequency to the current resonant frequency of the described resonant arrangement of the stationary primary side and the mobile secondary side of the power transfer transmission system.
One further component is the support circuit that is connected to the at least one half-bridge node in parallel to the resonant circuit. The support circuit comprises at least one energy storing element that is designed to receive electric energy and store the received energy during the respective half-cycle and to drive a support current using the stored energy during the respective next transient phase, wherein the support current adds to the load current in the inverter circuit and therefore contributes to charging and/or discharging parasitic capacitances of the switching units and by this supports shifting the potential of at least one of the half-bridge nodes between the plus potential and the minus potential. Thus, in the case that two half-bridge nodes are provided by an H-bridge, the two half-bridge nodes are connected to both the load and the support circuit individually or separately in the sense that the load and the support circuit are connected in parallel to each other. This ensures that the support circuit does not have an influence on the resonant behavior of the load.
One embodiment comprises that the energy storing element of the support circuit comprises one or more than one inductor. This at least one inductor interconnects the half-bridge nodes of two half-bridges. The at least one inductor receives the electric charging current from the inverter circuit during each half-cycle and is thus charged with energy. In the transient phases, the at least one inductor provides the support current using the stored energy. The support current then supplies the energy for charging and/or discharging the capacitance at the half-bridge nodes. The direction of the support current and the immediately preceding charging current are the same. The one or more inductor preferably each has a size in the range of 100 μH to 500 μH.
One embodiment comprises that said inductor of the support circuit comprises two windings that are connected in series between the half-bridge nodes of the inverter circuit and an electric connection between the two windings comprises at least one electric and/or electronic element. In one implementation, the windings are provided with the same number of turns or one number of turns is at the most 10% smaller than the other number of turns. This allows for a symmetric arrangement or a symmetric design of the switching circuit with respect to the half-bridge nodes of two switching units. As the switched voltage is also symmetric, this provides the benefit that for both half-cycles of a full switching cycle the support circuit has the same electrical behavior. Any additional electric element or electronic element may be added or provided in between the two windings.
One embodiment comprises that the electric connection between the two windings is connected to a ground potential by at least one circuit branch that comprises a respective Y-Capacitor. One single Y-capacitor may be provided in a single branch that may connect a single connecting node or tap between the two windings to the ground potential. Alternatively, two circuit branches with a respective Y-capacitor may be provided for connecting two nodes or taps between the two windings to the ground potential, and in between these two taps additional electric or electronic elements may be provided. For example, an arrangement of a DC-blocking capacitor and two Y-capacitors may be provided between the two windings. This yields a support circuit that may also short circuit the described HF signal components to a ground potential.
One embodiment comprises that the support circuit comprises an identical or a symmetric design regarding the resulting electric connection of each of the half-bridge nodes to the ground potential. The symmetric design may comprise a single circuit branch with its Y-Capacitor (no DC blocking capacitor provided). Alternatively, the symmetric design may comprise one DC blocking capacitor and two circuit branches. Alternatively, the symmetric design comprises one circuit branch and two DC blocking capacitors. With these combinations, DC blocking and/or reduction of HF signal components can be achieved and at the same time the support circuit may exhibit an identical electric behavior for both the positive half-cycle and the negative half-cycle.
One embodiment comprises that the respective circuit branch comprises a resistor for limiting a ground current. This prevents excessive heat generation in the case of an increased amounts of HF signal components, as a resistor helps dampening oscillations.
One embodiment comprises that the two windings are arranged on separate ferromagnetic cores. One embodiment comprises that the two windings are arranged on a common ferromagnetic core and the windings are electrically connected in series. The two windings act as a transformer. With regard to the half-bridge nodes, the inductance of the two windings add to provide the energy storing element. On the other hand, from the perspective of a ground potential to which the tap between the two windings may be connected, the inductances of the two windings subtract such that they do not block the filtering of HF signal components.
One embodiment comprises that the resonant circuit is connected to the inverter circuit and to the support circuit over a shielded cable and an electric shielding of the cable is connected to the ground potential at a ground connection point that is arranged at a distance to a ground connection point of the support circuit, wherein the distance is smaller than or less than 50 cm. In other word, the ground connection point of the shielding is very close the Y-Capacitor for short-cutting or short-circuiting the HF signal components. This design has proven beneficial for short-cutting HF signal components that may be caused by the parasitic capacitance that exists between the shielding and the cable itself. One embodiment comprises that the support circuit is electrically detached from a ground potential and comprises at least one inductor only or at least one inductor and at least one DC blocking capacitor for blocking a DC current through the support circuit. This arrangement can be used as an alternative where the two half-bridge nodes of an H-bridge are connected without additional connection to the ground potential. The inductor used can have a single winding. The resulting support circuit can be designed as an LC-link that is connected in parallel to the load, with no additional connection to the ground potential.
One embodiment comprises that the respective switching unit comprises at least one transistor and/or at least one thyristor and/or the respective freewheeling element comprises at least one diode, in particular a body diode. The at least one transistor and/or at least one thyristor acts as a respective switching element as has already been described. As a transistor, preferably a MOS power transistor (MOS—Metal-Oxide-Semiconductor) technology or MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) and/or IGBT (Insulated-Gate Bipolar Transistor) is used. Two H-bridges can be provided in the form of a so-called power module or power semiconductor module or power electronic module as it is available from the prior art. The invention enhances or supports such an H-bridge as an additional circuit that may be added in the described form. A freewheeling element may already be available as a component of a switching element in the form of the described body diode. If an additional freewheeling element is needed, one or more additional diodes may be provided.
The invention also comprises embodiments of the inventive power transmission device that comprise features that correspond to the features as they have already been described in connection with the embodiments of the inventive vehicle. Likewise, the invention also comprises embodiments of the inventive method that comprise the features that correspond to features as they have already been described in connection with the embodiments of the inventive power transmission device. For this reason, the corresponding features of the embodiments of the inventive method are not described here again. The invention also comprises the combinations of the features of the different embodiments.
In the following an exemplary implementation of the invention is described. The figures show:
The embodiment explained in the following is a preferred embodiment of the invention. However, in the embodiment, the described components of the embodiment each represent individual features of the invention which are to be considered independently of each other and which each develop the invention also independently of each other and thereby are also to be regarded as a component of the invention in individual manner or in another than the shown combination. Furthermore, the described embodiment can also be supplemented by further features of the invention already described.
In the figures identical reference signs indicate elements that provide the same function.
In the wireless power receiving system 12 an electric voltage and current may be induced in a receiving coil 16 of a resonant circuit 17 that may also comprise at least one capacitance 16′. Further on the mobile side, a passive or active rectifier 18 may be connected to the resonant circuit 17 and may feed directly a mobile energy system which may consist of several loads (e.g. DC/DC-converter, not shown) and/or the energy storage device 14 (e.g. battery modules, supercaps, ultracaps). A DC-link capacitor 19 may be provided. A switch 20 may be provided for controlling a charging current into the energy storage device 14.
On the primary side the wireless power transmission device 11 may comprise a resonant circuit 21 that may be connected as an electric load 22 to an inverter circuit 23 that may generate a switched voltage 24 between electric contacts or electric connectors 25, 25′ of the resonant circuit 21. Due to the switched voltage 24, a load current 26 may be evoked in the resonant circuit 21. In particular, the load current 26 is an AC (Alternating Current). The load current 26 may flow in a transmission coil 27 of the resonant circuit 21 which may generate the time-varying magnetic field 15 that induces the voltage and current and the receiving coil 16. At least one capacitive element 27′ may be provided in the resonant circuit 21 for achieving resonant characteristics. The resonant circuit 21 may be designed according to the prior art.
For generating the switched voltage 24 with a power transfer frequency f, the inverter circuit 23 may be operated or controlled by a control circuit 28 that may control two half-bridges 29A, 29B that may be operated together as an H-bridge 30. On an input side, the inverter circuit 23 may be connected to a DC source 31 which may provide a plus terminal or plus potential 32 and a minus terminal or minus potential 33 for connecting to the inverter circuit 23. The DC source 31 may be connected to an electric power network 34, which can be, for example, an AC 120-Volt or 230-Volt network. The DC source 31 may comprise in a known fashion a rectifier and/or a DC link. Each H-bridge 29A, 29B may be connected to both the plus potential 32 and the minus potential 33.
In each half-bridge 29A, 29B, two switching units 35H, 35L, 36H, 36L may be provided. The letter “H” stands for “high side”, the letter “L” for “low side” in the known fashion. In each half-bridge, the switching units 35 (i.e. 35H, 35L) and the switching unit 36 (i.e. 36H, 36L) are connected in series between the plus potential 32 and the minus potential 33, respectively. The electric connection between the switching units of the respective half-bridge is an output connector or half-bridge node A, B. To these two half-bridge nodes A, B, a respective one of the connectors 25, 25′ is connected. By controlling the switching units 35, 36, the control circuit 28 alternatingly connects the half-bridge nodes A, B to the plus potential 32 and the minus potential 33. In the following, the term “half-bridge node” is abbreviated as “node”, i.e. the half-bridge node A is termed “node A”, and the half-bridge node Bis termed “node B”.
In the wireless power transmission device 11, for switching of the switching units 35, 36, zero-voltage switching is supported by a support circuit 37. The support circuit 37 is connected in parallel to the load 22 with regard to the node A, B. In other words, both the load 22 and the support circuit 37 interconnect the nodes A, B independently from each other.
The support circuit 37 may be connected to node A via an electric connecting point or connector K1 and to the node B via a connecting point or connector K2. In particular, the connection between node A and connector K1 can be a direct connection without any further electrical component like a resistor or a capacitor or an inductor. Likewise, for the connection between node B and the connector K2 can be a direct connection without any further electric element like a resistor or a capacitor or an inductor may be provided. Thus, also an electric line, for example, an electric cable or an electric busbar, may provide the electric connection. Likewise, the connector 25 of the resonant circuit 21 to the node A can be designed without any further electrical component, i.e. without resistor or capacitor or inductor, but rather can be based on said electric line, i.e. the cable and/or busbar, for example. Likewise, the electric connector 25′ can be connected directly to node B via the electric like, e.g. the cable or busbar, especially without any further electric component like a resistor or capacitor or inductor. The respective connectors K1, K2, 25, 25′ can be, for example, a soldering point or a plug or in a simple case a segment or a section of a cable or busbar, respectively. In general, it represents the electric connection region where the electric current enters or leaves the support circuit 37 (connectors K1, K2) or the resonant circuit 21 (connectors 25, 25′), respectively.
A potential difference or supply voltage between the electric potentials 32, 33 as it may be generated by the DC source 31 may be in the range of 50 Volts to 2 Kilovolts.
A first diagram 44 shows the switching states of the H-bridges 29A, 29B by illustrating the electric potential of the respective nodes A, B. In the half-cycle T1, node A is connected to the plus potential 32 whereas with a phase shift of 180°, node B is connected to the minus potential 33. By changing the switching states of the switching units 35, 36 in the half-bridges 29A, 29B during the following transient phase 43, node A is connected to the minus potential 33 and node B is connected to the plus potential 32 in the next half-cycle T2. A full switching cycle 41 is finished by a second transient phase 43 following half-cycle T2. Then, for half-cycle T3 this pattern is repeated.
During the transient phases 43, a shifting S of the electric potential of the respective node A, B to one of the potentials 32, 33 of the DC source 31 to the respective other potential 32, 33 must be achieved.
A diagram 45 shows an optimal wave form Ic1 of the resulting current 51. Diagram 45 shows a case where the power transmission frequency f matches the resonant frequency of the resonant arrangement comprising the resonant circuit 21 and the resonant circuit 17. An optimal current waveform Ic1 for the load current 26 may result (ideal resonant switching with the power transmission frequency f being set to the true resonance frequency of the resonant arrangement).
A diagram 46 shows sub-optimal wave form Ic2 of the resulting current 51 (non-ideal resonant switching with the power transmission frequency f being set to a different value than the true resonance frequency of the resonant arrangement, for example, f is too low). Diagram 46 shows a case where the power transmission frequency f does not match the resonant frequency of the resonant arrangement (not ideally tuned case). The sub-optimal current waveform Ic2 for the load current 26 may result. At the end of each half-cycle 42 during the transient phase 43 there is less load current 26 for a resonant voltage transition.
The following observation has been made that forms the basis of this disclosure. Under some operating conditions the current Ic2 has a high peak factor and then a tail with little energy in each half-cycle. In this case, the current is not high enough to commutate the voltage in the inverter circuit completely during the transient phases 43. This means that maintaining zero-voltage switching in the primary side is not possible, resulting in high EMI and switching losses.
The highly variable current at the end of the switching half-cycle 42 also means that the speed of commutation is poorly defined, a high current leads to high dv/dt (derivative of voltage v with respect to time t) and fast switching edges which cause resonance in the coil system. If the current is low, then the transition is at first slow and then hard switched again exciting coil resonance. The switching of the transistors or other switching units of the inverter circuit can be slowed down, but this results in high switching losses.
A diagram 47 shows the wave form Is of the overall additional current 50 through the support circuit 37. This additional current 50 charges the energy storing element 40 with energy during the half-cycles 42 and this energy is then available in the following transient phase 43 for driving the support current 50A. Thus the additional current 50 (Is) can be considered to have two successive or alternating phases, a charging phase and a commutation phase. The charging phase corresponds to the half-cycle 42 where energy is being stored in the at least one inductor by building up the charging current 50A. The commutation phase corresponds to the transient phase 43 where the at least one inductor supplies the support current 508. The support circuit 37 therefore provides the support current 508 during the transient phase 43 that adds to the load current 26 during the transient phase 43 ensuring that the strength or absolute value of the commutated resulting current in the inverter circuit 23 is larger as compared to the case shown in diagram 46, i.e. in the sub-optimal tuning case. During the transient phase 43, the resulting current 51 is also denoted here as commutated resulting current 51′. For the example shown, an inductor L and a DC blocking capacitor (L=300 μH and C=100 nF) were used.
A diagram 48 shows that the resulting current 51 is the sum Ic2+Is of the load current 26 and the support current 50. The diagram 48 shows the resulting wave form of the resulting current 51 in the case of the wave forms Ic2 and Is. A comparison between the diagram 46 and 48 shows that during the transient phases 43, the resulting current in the inverter circuit 23 has a higher absolute value than without the support current from the support circuit 37.
In parallel to each switching element 60, a freewheeling element 61a, 61b, 61c, 61d may be provided, for example, as a diode or a body diode. The exemplary half-cycle 42 shown in
While
Another term for the shown parasitic capacitances is Coss. Coss is also known as the output capacitance which is the sum of gate-drain and drain-source capacitance in a FET (field effect transistor). It influences turn-off characteristic and loss with light load. The greater Coss, the lower the turn-off dv/dt.
By setting the switching element 60a in the off state 62 for the transient phase 43 in
As the support circuit 37 drives the support current 50B during the transient phase 43 and thus supports or helps charging and/or discharging the parasitic capacitances 65a, 65b in the switching units 35, 36 such that although the load current 26 might not be sufficiently large enough, the support current 50B yields a resulting commutated current 51′ that may charge and/or discharge the parasitic capacitances 65a, 65b of the switching units 35,36 with the energy from the energy storing element 40 of the support circuit 37. Driving the support current 50B is achieved by inductance in the case of an energy storing element 40 in the form of at least one inductor.
With an energy storing element 40 in the form of an inductor, the value of the inductance can be in the already described range for ensuring that a difference between the electric potential of the node A and the minus potential 33 (in the case of the half-cycle T1) is minimal, i.e. the resulting voltage 66 is in the ideal case a zero- voltage for switching the switching unit 35L in the case shown in
According to the example shown in
In the example of
This provides a protection against EMI: The shielding is an EMI screen of the cables. The cables to the coil have switched voltages which are capacitively coupled into the screen. This results in a current in the screen which is then connected to the chassis or casing (at ground potential). The resulting current needs a path back to its source, the windings of the inductor provide a short and direct path through the Y-Capacitor back to the transistors or other switching units. This works as each inductor winding has half the bridge voltage and so assuming the bridge is symmetrical the mid-point is static so can be connected to ground.
Any embodiment of the support circuit may comprise an electric or electronic switch that may be provided for blocking the electric current through the switching circuit. This provides the advantage that the switching circuit may be deactivated in the wireless power transmission device. The switch may be based on a transistor or a relay. In one version the switch may be controlled by a sensing circuit that senses an electric or thermal quantity that is indicative of the need for the support current (see
In the following, further preferred embodiments are described.
Thus, adding an extra inductor in parallel to the transistor bridge, adds a defined current and ensures there is always enough energy to create resonant switching. As the energy for cummutation is defined as LI2. L is the inductance of the energy storing element and it is constant and the current is proportional to the switched voltage (as the power switching frequency hardly changes), which is beneficial as the commutation energy required is also proportional to the voltage. The current strength I is the charging current at the end of each half-cycle. Note that this extra current needed is output off phase with the coil current and has a minor effect on the RMS current in the switching circuit (RMS—root mean square). Another advantage is that the systems can be dimensioned differently and so operated closer to the optimal frequency and the inductor eliminated capacitive switching for the transistors.
To ensure that there is no DC current in the inductor a DC blocking capacitor can be added, if the winding is split into 2 windings, the middle point will be close to a constant voltage. This can then be used as part of the EMI design and connected to ground using Y capacitors as shown in
The following aspects may be provided alone or in combination:
Overall, the example shows how a reduction of losses and EM radiation in a converter of an inductive charging station can be achieved.
The invention is also directed to the following aspects:
Aspect 1: Method for operating an inverter circuit (23) in a wireless power transmission device (11), wherein the inverter circuit (23) comprises at least one half-bridge (29A, 29B) with two switching units (35H, 35L, 36H, 36L) that each have a parasitic capacitance (65) and that each comprise a freewheeling element (61), wherein in the respective half-bridge (29A, 29B) the first switching unit (35H, 36H) links a plus potential (V+) of a DC source (31) to a half-bridge node (A, B) and the second switching unit (35L, 36L) links the half-bridge node (A, B) to a minus potential (V−) of the DC source (31), and wherein a resonant circuit (21) for the wireless power transmission is connected as a load (22) to the half-bridge node (A, B), wherein the resonant circuit (21) comprises a transmission coil (27) and at least one capacitive element (27′), and for providing a switched voltage (24) at the half-bridge node (A, B) a switching cycle is repeatedly performed at a power transfer frequency (f), wherein the switching cycle (41) comprises that a control circuit (28) alternatingly connects the half-bridge node (A, B) to the plus potential (V+) in one half-cycle (42) and to the minus potential (V−) in the other half-cycle (42) by setting the corresponding switching unit (35H, 36L) into an on state (62) while keeping the respective other switching unit (35L, 36H) in an off state (63) and for alternating between the half-cycles (42) a transient phase (43) is performed wherein the switching unit (35H, 36L) that is currently in the on state (62) and provides an electric load current (26) to the load (22) is set into the off state (63) which commutates the load current (51′) to the freewheeling element (61) of the other switching unit (35L, 36H) such that the parasitic capacitances (65) of the switching units (35H, 35L, 36H, 36L) are charged and/or discharged and by this the electric potential of the half-bridge node (A, B) is shifted from the respective current potential (V+, V−) to which is has been connected to, to the respective other potential (V−, V+), and the transient phase (43) is finished by a zero-voltage switching, ZVS, of the other switching unit (35L, 36H) into the on state (62), characterized in that an additional support circuit (37) is connected in parallel to the load (22), wherein the support circuit (37) comprises at least one energy storing element (40) that is charged with energy by a charging current during (50A) in the respective half-cycle and in the respective following transient phase (43) the support circuit (37) drives a support current (508) using the stored energy from its at least one energy storing element (40), wherein the support current (508) adds to the commutated load current (51′) in the inverter circuit (23) and therefore contributes to the charging and/or discharging of the parasitic capacitances (65) of the switching units (35H, 35L, 36H, 36L) and by this supports shifting the potential of the half-bridge node (A, B).
Aspect 2: Method according to aspect 1, wherein two half-bridges (29A, 29B) are provided that each comprise a half-bridge node (A, B) and that are operated as an H-bridge (30) for providing the switched voltage (24) between the two half-bridge nodes (A, B) and wherein the load (22) and the support circuit (37) are connected to the two half-bridge nodes (A, B).
Aspect 3: Method according to any of the preceding aspects, wherein a DC current through the support circuit (37) is blocked by at least one DC-blocking capacitor (71, 71′) of the support circuit (37) and/or wherein a fundamental component of the current (50) through the support circuit (37) is out of phase with regard to the load current (26).
Aspect 4: Method according to any of the preceding aspects, wherein high frequency, HF, signal components (90) of the load current (26) with a frequency of at least twice the power transfer frequency (f) are lead to a ground potential (75) by at least one Y-capacitor (78, 78′) of the support circuit (37).
Aspect 5: Method according to any of the preceding aspects, wherein the power transfer frequency (f)is in a range from 20 KHz to 150 KHz.
Aspect 6: Wireless power transmission device (11) for an inductive electric power transmission, wherein the power transmission device (11) comprises: a resonant circuit (21) for emitting the power to a receiving coil (16), wherein the resonant circuit (21) comprises at least one transmission coil (27) and at least one capacitive element (27′), an inverter circuit (23) with at least one half-bridge node (A, B) to which the resonant circuit (21) is connected for receiving both a switched voltage (24) and a load current (26), wherein the inverter circuit (23) comprises at least one half-bridge (29A, 29B) with two switching units (35H, 35L, 36H, 36L) that each comprise a freewheeling element (61), wherein the first switching unit (35H, 36H) links a plus potential (V+) of a DC source (31) to the respective half-bridge node (A, B) and the second switching unit (35L, 36L) links the same half-bridge node (A, B) to a minus potential (V−) of the DC source (31), and a control circuit (28) for controlling the switching units (35H, 35L, 36H, 36L) of the at least one half-bridge (29A, 29B), wherein the control circuit (28) is designed to repeatedly perform a switching cycle (41) at a power transfer frequency (f), wherein each switching cycle (41) comprises two half-cycles (42) and the half-cycles (42) are separated by a respective transient phase (43) where the switching units (35H, 35L, 36H, 36L) are set to an off state (63) and the load current (26) commutates to at least one freewheeling element (61), characterized in that a support circuit (37) is connected to the at least one half-bridge node (A, B) in parallel to the resonant circuit (21), wherein the support circuit (37) comprises at least one energy storing element (40) that is designed to receive electric energy and store the received energy during the respective half-cycle (42) and to drive a support current (50B) using the stored energy during the respective next transient phase (43), wherein the support current (50B) adds to the load current (26) in the inverter circuit (23) and contributes to charging and/or discharging parasitic capacitances (65) of the switching units (35H, 35L, 36H, 36L) and by this supports shifting the potential of at least one of the half-bridge node (A, B) between the plus potential (V+) and the minus potential (V−) in the transient phase (43).
Aspect 7: Power transmission device (11) according to aspect 6, wherein the energy storing element (40) of the support circuit (37) comprises at least one inductor (70) that interconnects the respective half-bridge nodes (A, B) of two half-bridges (29A, 29B) of the inverter circuit (23) and that is designed to receive an electric charging current (50A) from the inverter circuit (23) in the respective half-cycle (42) for getting charged with energy and that is designed to drive the support current (50B) by inducing a voltage using the stored energy.
Aspect 8: Power transmission device (11) according to aspect 7, wherein the at least one inductor (70) of the support circuit comprises two windings (73, 73′) that are connected in series between the half-bridge nodes (A, B) of the inverter circuit and an electric connection between the two windings (73, 73′) comprises at least one electric and/or electronic element.
Aspect 9: Power transmission device according to aspect 8, wherein the electric connection between the two windings (73, 73′) is connected to a ground potential (75) by at least one circuit branch (77, 77′) that comprises a respective Y-Capacitor (78, 78′).
Aspect 10: Power transmission device (11) according to aspect 9, wherein the support circuit (37) comprises a symmetric design regarding the resulting electric connection of each of the half-bridge nodes (A, B) to the ground potential (75) and the symmetric design comprises a single circuit branch (80) with its Y-Capacitor (78) or one DC blocking capacitor (71) and two circuit branches (77, 77′) or one circuit branch (80) and two DC blocking capacitors (71, 71′).
Aspect 11: Power transmission device (11) according to aspect 9 or 10, wherein the respective circuit branch comprises a resistor (81) for limiting a ground current and/or damping an oscillation of the ground current.
Aspect 12: Power transmission device (11) according to any of aspects 8 to 11, wherein the two windings (73, 73′) are electrically connected in series and are arranged on a common ferromagnetic core or wherein the two windings (73, 73′) are arranged on separate ferromagnetic cores.
Aspect 13: Power transmission device (11) according to any of aspects 8 to 12, wherein the resonant circuit (21) is connected to the inverter circuit (23) and to the support circuit (37) over a shielded cable (91) and an electric shielding (92) of the cable (91) is connected to the ground potential (75) at a ground connection point (99) that is at a distance (97) to a ground connection point (98) of the support circuit (37), wherein the distance (97) is smaller than 50 cm.
Aspect 14: Power transmission device (11) according to any of aspects 6 to 8, wherein the support circuit (37) is electrically detached from a ground potential (75) and comprises a) at least one inductor (70) only orb) at least one inductor (70) and at least one DC blocking capacitor (71) for blocking a DC current through the support circuit (27).
Aspect 15: Power transmission device (11) according to any of aspects 6 to 14, wherein the respective switching unit (35H, 35L, 36H, 36L) comprises at least one transistor (60) and/or at least one thyristor and/or the respective freewheeling element (61) comprises at least one diode, in particular a body diode.
A description has been provided with particular reference to examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims, which may include the phrase “at least one of A, B and C” as an alternative expression that refers to one or more of A, B or C, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004).
| Number | Date | Country | Kind |
|---|---|---|---|
| 21 170 584.3 | Apr 2021 | EP | regional |
This application is a U.S. national stage of International Application No. PCT/EP2022/061226, filed on Apr. 27, 2022, which claims the priority benefit of European Patent Application No. 21170584.3 filed on Apr. 27, 2021. Both the International Application and the European Patent Application are incorporated by reference herein in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/061226 | 4/27/2022 | WO |
