Inductive power transfer pad and method for manufacturing an inductive power transfer pad

Abstract

The invention relates to an inductive power transfer pad (10), in particular to a power transfer pad (10) for a system for inductive power transfer to a vehicle, comprising a stationary part (14) and a movable part (12), wherein the movable part (12) is movable between a retracted state and an extended state, wherein the movable part (12) further comprises a primary winding structure (26) and at least one inverter (34) electrically connected to the primary winding structure (26). Furthermore, the invention also relates to a method for manufacturing such an inductive power transfer pad (10).

Description

Technical Field

[0001] The present invention relates to an inductive power transmission plate and a method for manufacturing an inductive power transmission plate, and particularly to an inductive power transmission plate for transmitting electrical energy to a vehicle. Background Technology

[0002] Electric vehicles, particularly rail vehicles and / or highway vehicles, can operate using electrical energy transmitted via inductive power transfer. Such vehicles may include electrical circuitry, which may be part of the vehicle's traction system, including a receiving device adapted to receive alternating electromagnetic fields and generate alternating current through electromagnetic induction. Furthermore, such vehicles may include a rectifier adapted to convert alternating current (AC) to direct current (DC). The DC power can be used to charge the traction battery or to power the motor. In the latter case, an inverter can convert the DC power back to AC.

[0003] Inductive power transfer is achieved using two sets of windings, such as a three-phase winding. The first set is mounted on the ground (primary winding) and can be powered by a wayside power converter (WPC). The second set of windings is mounted on the vehicle. For example, the second set of windings can be mounted under the vehicle, such as under some carriages of a tram. For automobiles, it can be mounted to the chassis. The second set of windings, or the secondary side in general, is often referred to as the pickup or receiver. The first and second sets of windings together form a high-frequency transformer that transfers electrical energy to the vehicle. This can be done both statically (when the vehicle is not moving) and dynamically (when the vehicle is moving).

[0004] Especially in the case of highway vehicles, the fixed primary unit comprises multiple elements that are typically spatially separated. Typical known inductive power transfer systems include movable primary elements to reduce the gap between the primary and secondary units. US 5,654,621 A discloses an inductive transmitter having a primary element and a secondary element mounted on a vehicle, wherein the primary element is powered to move in all three spatial coordinates within a predetermined spatial region. WO 20151128450 A1 similarly discloses a movable primary element housing a primary winding structure.

[0005] Up to this point, movable (primary) components typically house only the primary winding structure, without housing power electronic devices, such as inverters, for supplying power to the primary winding structure. Conversely, as in the case of WO 2015 / 128450 A1, additional components such as inverters are housed in the fixed section.

[0006] Currently available inductive power transfer boards, especially those that include moving parts, still suffer from high production costs and reliability issues.

[0007] Therefore, one object of the present invention is to improve the inductive power transmission board in terms of cost and / or reliability, and in particular to improve the inductive power transmission board including movable parts.

[0008] This objective is achieved by the apparatus and method according to the appended independent claims. Beneficial embodiments are defined in the dependent claims. Furthermore, unless otherwise explicitly stated, features mentioned in the introductory section of this specification may be provided individually or in any combination thereof in the currently disclosed solution.

[0009] The inventors have discovered that there are many drawbacks to separating the electronic power equipment and the primary winding structure into the fixed and moving parts of the inductive power transmission board.

[0010] First, electrical connectors (i.e., cables) are required to connect the power electronics in the stationary section to the primary winding structure in the movable section. Due to the movement of the movable section, these cables also move frequently and may be subjected to stress. This increases the risk of damage (e.g., cable breakage), thus reducing reliability. Furthermore, these cables may be relatively long, also contributing to increased costs.

[0011] Furthermore, even if the space between the movable and fixed parts can be at least partially surrounded by a cover element (e.g., a foldable and / or flexible bellows), it is generally necessary to seal the winding structure and / or power electronics, especially any electrical connections between them. This particularly includes the need for waterproof sealing. However, by distributing the aforementioned components between the movable and fixed parts, additional (electrical) interfaces and / or connection terminals are required at both the movable and fixed parts. Each of these multiple interfaces and connection terminals needs to be sealed, or in other words, needs to form a sealed connection with, for example, the cable connecting the movable and fixed parts. This increases cost and effort.

[0012] Another consequence of distributing the aforementioned components between the movable and fixed parts is the need to provide a separate housing part for each of these components. This increases the tooling costs for producing the corresponding number of individual housing components, for example, increasing the cost of production via injection molding or die casting.

[0013] Furthermore, when viewed from above (e.g., when viewing the inductive power transmission panel from below), the fixed and movable portions are typically arranged adjacent to each other (i.e., not completely overlapping or not overlapping at all). This is necessary to limit the height of the power transmission panel when the movable portion is in the retracted state. However, this increases the size of the power transmission panel, more specifically, at least its horizontal dimension. This increase in size is accompanied by, for example, an increase in the cost of a larger housing assembly.

[0014] Finally, power electronic devices, especially inverters, typically require cooling. When placed in a fixed location, effective cooling has historically been difficult to achieve. For example, since the fixed portion is usually at least partially exposed rather than completely covered by movable parts, there is a risk that the movable parts can be touched by the user. Therefore, power electronic devices, as heat sources, cannot typically be placed close to the surface of the fixed portion. Instead, they need to be located inside the fixed portion, for example, at a distance from its outer surface. However, this makes it difficult to conduct heat from within the fixed portion to the surrounding environment and may require additional, expensive measures, such as powerful airflow circulating fans, additional metal cooling fins or cooling plates, or channels for circulating airflow within the fixed portion. If airflow is used for cooling, the airflow typically must be guided over long distances and, especially, circulated within the fixed portion, thus limiting its heat dissipation capacity. Summary of the Invention

[0015] To overcome at least some of the problems mentioned above, this application proposes that both the inverter (or a power electronic device for supplying power to the primary winding) and the primary winding structure be placed in the movable portion.

[0016] This allows for shorter electrical connections (i.e., cables) between the inverter and the primary winding structure, thus reducing costs. Furthermore, because the inverter and primary winding structure move together rather than relative to each other, the electrical connections between them are subjected to less stretching and / or compression. This limits the risk of damage and improves reliability.

[0017] Furthermore, the inverter and primary winding structure can be arranged in a manner that at least partially overlaps or even completely overlaps, thereby reducing the size (especially the space occupied) of the inductive power transfer board. This also offers the potential for cost savings.

[0018] Furthermore, the number of (separate) housing components can be reduced. According to one embodiment, the inverter can be housed and at least mechanically supported or housed within a single housing component of a movable portion. Therefore, production tooling costs can be reduced.

[0019] More specifically, an inductive power transfer board is proposed, particularly a power transfer board for a system for transferring inductive power to a vehicle, comprising a fixed (stationary) portion and a movable portion, wherein the movable portion is movable (e.g., movable relative to the fixed portion) between a retracted state and an extended (extended) state, wherein the movable portion further comprises a primary winding structure and at least one inverter electrically connected thereto. The inverter can typically be configured to power the primary winding structure, allowing inductive power transfer to occur (i.e., generating a desired electromagnetic field, for example, of a desired strength).

[0020] An inductive power transfer board can be the main unit of a system for inductive power transfer. When the primary winding structure is energized or when operating current is provided by an inverter or the like, the primary winding structure is configured to generate an alternating (electro)magnetic field.

[0021] The power transmission plate may include at least one actuator, wherein the movable portion can be moved by at least one actuator. In the context of this invention, the term "actuator" may refer to an entity consisting of all components or elements that cause the movable part to move. Therefore, the term "actuator" may include at least one actuating device and / or at least one lifting mechanism. Furthermore, the actuator may include a coupling device for mechanically coupling the actuating device and the lifting device and / or at least a guiding device for guiding the movement of the movable part. Known guiding devices are scissor legs connecting the movable part and the fixed part.

[0022] The movable part can move at least in a first direction (movement direction), specifically by means of at least one actuator. The first direction can be parallel to the main propagation direction of the electromagnetic field generated by the primary winding structure. In particular, the first direction can be perpendicular to the bottom surface of the power transmission plate or the ground surface on which the power transmission plate is mounted, wherein the first direction points away from the ground. Reverse movement can also be used for the retracted state.

[0023] In one example, the first direction aligns with the vertical direction, and therefore with the axis of gravity. In the following text, the terms “up,” “down,” “lower,” “highest,” and “bottom” refer to positional relationships in the vertical direction.

[0024] In the retracted state, the movable part, particularly its upper surface, can be positioned in the retracted position, especially relative to a predetermined lowest vertical position in the first direction. In the retracted state, the height of the power transmission plate, for example, the distance from the highest point of the power transmission plate to the upper surface of the movable part along the first direction, can be minimized. Correspondingly, in the extended state, the movable part, particularly its upper surface, can be positioned in the extended position, for example, a predetermined highest vertical position. In the extended state, the height of the power transmission plate is maximized. The mounting portion can correspond to the bottom surface of a power transmission plate, particularly the bottom surface of the fixed portion. The mounting portion can be used to mount the power transmission plate to a mounting structure, particularly to a floor surface. The retracted and extended states can be maintained by mechanical elements, such as blocking elements and / or brakes.

[0025] The (vertical) height of the power transmission board in the retracted state can be selected from the range of 50mm to 10mm, especially from the range of 70mm to 90mm.

[0026] Preferably, the height in the retracted state can be equal to 80 mm. The height in the extended state can be selected, for example, from the range of 95 mm to 155 mm, particularly from the range of 115 mm to 135 mm. Preferably, the height in the extended state can be equal to 125 mm.

[0027] The primary winding structure may include at least one phase line, such as a single phase line carrying one phase of alternating current. The at least one phase line of the primary winding structure may have a zigzag or looped path. In one example, at least one phase line of the primary winding structure may be designed such that the path of the phase line provides an even or odd number of sub-windings arranged adjacent to each other. In this context, a sub-winding represents a conductor loop, preferably a complete conductor loop that encloses a predetermined region. The conductor loop may provide or include one or more turns of a corresponding sub-winding. Adjacent to each other means that the central axes, particularly axes of symmetry, of the sub-windings are spaced apart from each other, for example, along a common straight line, for example, at a predetermined distance corresponding to the direction of extension of the primary winding structure. Further, the orientation of at least one phase line of the primary winding structure may be figure-eight shaped. This means that the phase line includes two, for example, circular sub-windings arranged adjacent to each other. In particular, the primary winding structure may include three phase lines.

[0028] Furthermore, the inductive power transmission board may include, more specifically, a movable portion thereof, a cable-carrying element. The cable-carrying element may be adapted to position and / or retain the primary winding structure, particularly to position line portions and / or phase wires within the primary winding structure. This can be accomplished by providing recesses and / or grooves in which the line portions of the phase wires are placed to define and retain any of the aforementioned primary windings, lines, or loops.

[0029] The cable carrier element can be made of non-metallic materials, such as plastic. It can be supported and / or at least partially overlapped or at least partially covered by a base member of a movable component discussed below. The cable carrier element and the base member can be surrounded by a sealing cap and / or connected to each other via a seal or a seal located between them. In particular, a waterproof connection and / or seal can be provided between the cable carrier element and the base member. Furthermore, the cable carrier element (and / or an outer cover connected to the cable carrier element, which covers at least a portion of the primary winding structure located between the housing and the cable carrier element) can serve as a cover for the base member, particularly as a cover for components (e.g., inverters) disposed on the base member.

[0030] Typically, the movable parts can preferably be encapsulated in a waterproof manner in the primary winding structure and inverter to increase reliability. This can be achieved, for example, by the arrangement of the cable-carrying elements in the outer cover, and / or in a particularly reliable and cost-effective manner.

[0031] Furthermore, the inductive power transfer board, particularly the movable portion, may include magnetic shielding elements. These magnetic shielding elements can be used to shield the external areas of the inductive power transfer board from the electromagnetic fields generated during inductive power transfer. The movable parts discussed below, and particularly their housing parts and / or base members, may provide corresponding magnetic shielding functions and / or function as corresponding magnetic shielding elements. However, additional magnetic shielding elements may also be provided, for example, at least covering the inverter, particularly the portion of the inverter facing the primary winding structure.

[0032] According to another embodiment, the movable part has no electrical connection to the fixed part, i.e., it is not electrically connected to the fixed part. This limits the number of electrical connections between these components, and in particular, limits the number of electrical interfaces that need to be sealed.

[0033] Alternatively, an electrical connection may exist, but the movable part (or at least the primary winding structure) may not receive any electrical energy from the fixed part or may only receive less electrical energy than is required to energize the primary winding structure. This is possible but not preferred according to the invention when the actuator is integrated into the fixed part; the movable part may transfer electrical energy to the actuator and thus to the fixed part, but it preferably does not receive electrical energy from the fixed part.

[0034] According to another embodiment, the stationary portion contains no electrical components, particularly none for powering the primary winding structure. Therefore, the stationary portion can be a purely mechanical system, for example, providing stability and support for the movable portion. When electrical components are included in the stationary portion, these components preferably cannot cause movement of the movable portion and / or generate an electric field in the primary winding structure. In particular, when electrical components are included in the stationary portion, these components preferably do not interact with the movable portion and / or are not connected to the movable portion. This also limits the cabling between these components and the need for sealed electrical connection interfaces.

[0035] In another example, for connection to an external power source, the movable part includes connection terminals (e.g., connection terminals for connecting cables) and / or a connecting cable. The movable part can therefore be connected to or be accessible to the connecting cable via the connection terminals, etc. The external power source can be a household power supply or, for example, a household power grid connected to a public power grid. The connecting cable can therefore include a plug for connecting to a socket. The plug can be replaced to suit local specifications and standards. Furthermore, the cable length can also be adjustable, for example, by connecting the connecting cable to another cable portion, preferably a cable portion including a plug, via an interface including an interface.

[0036] The connecting cable can be interchangeably connected to the connecting terminal, for example, by manually inserting into or removing from the connecting terminal. Alternatively, it can be secured to the connecting terminal without manual insertion and removal, for example, by a simple manual push or pull operation. For example, the connecting cable can be soldered, tinned, or glued to secure it to the connecting terminal. Additionally or alternatively, a preferred permanent wire connection can be formed between the cable and the connecting terminal, which cannot be removed by the user without tools and / or without damaging the wire connection.

[0037] The connection terminals may be located in a space at least partially surrounded by the cover member discussed below. The connection cable can be guided from within this space to the outside. For this purpose, an opening may be provided within the cover member (see below). The connection terminals are generally considered to remain in a fixed position, but the route of the connection cable from the inductive power transfer board to the external power source can be flexibly adjusted, for example, by guiding the connection cable from the aforementioned space to the outside through various options. This allows the user to choose how to position the connection cable, for example, avoiding the need for him to drive through it (thus temporarily compressing the cable) to position his vehicle above the inductive power transfer board.

[0038] In a preferred example, the connecting cable may be guided from the space to the outside at least on a first side and a second side of the inductive power transmission plate, wherein the first side and the second side are preferably located at opposite ends, sides or faces of the inductive power transmission plate.

[0039] According to another embodiment, the inductive power transmission board further includes an actuator for moving the movable portion, wherein the actuator is electrically connected to and / or powered by the movable portion. Specifically, the actuator can receive electrical energy from the movable portion for moving the movable portion. The actuator's connection terminals can be positioned such that it cannot move relative to the movable portion; for example, a portion of a brake is fixedly connected to the movable portion. This restricts movement of the electrical connection located between the movable portion and the brake, particularly limiting frequent extension or compression of the electrical connection therein, thereby limiting the risk of cable breakage.

[0040] Furthermore, the electrical connection between the movable part and the actuator can be formed within a space primarily surrounded by a cover member as discussed herein. This may reduce sealing requirements compared to a connection formed on the outside of the inductive power transmission plate.

[0041] Additionally, the movable part can be configured to supply power to the actuator from an external power source. In other words, electrical energy from an external power source can be directed and / or forwarded to the movable part, and from there to the brake. This eliminates the need for the brake to be directly connected to an external power source, reducing the number of separate power cables and associated costs.

[0042] Typically, an inductive power transfer board may consist of only a single cable or connector for connecting to an external power source, and this cable or connector may be included in and / or connected to a movable portion. The movable portion can then be used as a distributor to distribute electrical energy received from the external power source to other units, such as an inverter, the aforementioned actuator, or the airflow generation unit mentioned below.

[0043] The actuator may typically include a telescopic cylinder or similar telescopic mechanical component. To provide the corresponding extension or retraction, the actuator may include an electric motor or electric pump, such as an electro-hydraulic pump or a pneumatic pump.

[0044] According to another example, the actuator is mechanically rested against a fixed portion. In other words, the actuator can be supported by the fixed portion, for example, by using the fixed portion as a fixed base with an extension portion to push the movable portion upward relative to the fixed portion. The actuator can be fixed to the fixed portion directly or indirectly. Additionally or alternatively, the actuator can typically be fixed directly or indirectly to the movable portion and / or rest against the movable portion. However, as mentioned above, it is preferable that there is no electrical connection with the fixed portion, and the actuator's electrical power is provided by the movable portion, for example, by connecting the movable portion to an external power source.

[0045] According to a further embodiment, the inductive power transmission board also includes an airflow generating unit electrically connected to an interior powered by a movable part. The airflow generating unit can, for example, move together with the movable part. Electrical connections can be formed such that the airflow generating unit does not move relative to the movable part, for example, by placing a cable between a connection terminal of the airflow generating unit and the movable part, wherein the connection terminal (or generally the airflow generating unit) is fixed to the movable part and / or stationary relative to the movable part. This reduces the required cable length, thereby reducing cost and the risk of cable breakage.

[0046] The airflow generating unit may be a fan or include a fan. It can generate airflow directed to or along a portion of the movable part, for example, toward or along its bottom surface facing the fixed part. Typically, the airflow can be directed to or along a portion close to a heat source, such as an inverter or other electrical component. Therefore, it can be directed to or along a portion or surface of a base member, for example, housing the movable part of the inverter or electrical component. The airflow can flow at least partially within the space enclosed by the cover member discussed below.

[0047] The movable part can be configured to supply electrical energy from an external power source to the airflow generating unit. Similar to the power supply for the actuators discussed above, this can be achieved by the movable part conducting electrical energy from an external power source to the airflow generating unit.

[0048] In this configuration, the airflow generating unit can be located at or within the movable part. This allows the airflow generating unit and the movable part to be linked, which is advantageous in many ways, as it provides a durable and inexpensive electrical connection between them.

[0049] For example, the airflow generating unit can be placed on the lower side of the movable portion facing the fixed portion. Specifically, it can be positioned within the space surrounded by the cover member discussed below. Additionally or alternatively, the airflow generating unit can be placed near a heat source within the movable portion, for example, adjacent to it. Furthermore, it can be positioned such that airflow can be generated along the high-temperature portion of the movable portion. In one example, the airflow generating unit is located at the edge of the movable portion (or at least off-center from the center of the movable portion) to guide airflow along a corresponding long portion of the movable portion (e.g., preferably along at least half the length or width of the bottom side of the movable portion).

[0050] In one example, the airflow generating unit can be used to generate ambient airflow and flow along and / or within the movable portion. In this regard, air can be drawn from the surrounding environment to generate the airflow, and then released back into the environment. Therefore, the inductive power transfer plate can include at least one air inlet and at least one air outlet, and the airflow generating unit can be configured to generate airflow between them. This helps to provide effective heat removal, compared to the rapid heating but insufficient heat removal in all relevant parts, resulting from, for example, the circulation of air in a long channel for cooling in a known stationary component.

[0051] According to a further embodiment, the movable portion includes a base member that supports (or, in other words, carries) the primary winding structure and / or the inverter, but does not necessarily contact it. The base member may be plate-like, but may include grooves, recesses, through-holes, etc. It may form the bottom surface of the movable portion. Guiding devices such as scissor legs and / or actuators for providing movement force to the movable portion may be attached to the base member. The base member may form part of a preferably sealed, and more preferably waterproof, sealed enclosure provided by the movable portion for housing the inverter and / or the primary winding structure.

[0052] In this respect, the inverter can be at least partially positioned between the base member and the primary winding structure, particularly when viewed along the axis of motion of the movable portion (e.g., when viewed along a vertical axis). For example, the inverter can be covered by the base member from at least one side, preferably from at least three or five sides. According to another embodiment, this can be achieved directly, for example, by at least partially arranging the inverter in a recess within the base member. This helps protect the inverter from external influences, such as moisture. Furthermore, this helps to position the inverter (which typically represents a potential heat source) close to the base member and thus close to the outside. Therefore, heat from the inverter can be effectively conducted to the outside. For example, the resulting airflow can be directed away along a portion of the base member that houses the inverter.

[0053] Typically, the inverter can be positioned on the side of the base member facing the primary winding structure. Conversely, the airflow generating unit can be located on the opposite side of the base member, such as the underside of the base member. The latter can effectively cool the unit by guiding airflow along the outer side of the base member, without needing to provide air inlets or outlets within the movable portion. These additional interfaces and / or openings provided in the movable portion would allow moisture to enter through them, resulting in significant sealing work.

[0054] In one example, multiple electrical components are provided, which can be summarized into at least two groups or functional units. Each of the functional unit groups is arranged in a recess within a base member. Preferably, an airflow generating unit is disposed between these recesses (but possibly on opposite sides of the base member, such as its underside). This provides effective cooling because the heat sources can be spatially distributed, thus avoiding localized heat concentration. Furthermore, heat dissipation from multiple groups of heat sources may be achieved with only a single airflow generating unit.

[0055] Recesses can form protrusions on the underside of the base member. Channels or recesses (e.g., defined by their respective sidewalls) can be defined between adjacent recesses (or more precisely, the resulting protrusions). These channels or recesses can thus guide the airflow generated by the airflow generating unit along the base member in a desired manner. This reduces the additional components required to define individual channels, thereby lowering production costs.

[0056] In a preferred example, the base member is made of a metallic material. Typically, a metallic material with a higher average thermal conductivity than the selected metallic materials can be chosen. By selecting a metallic material, heat sources, such as the inverter housed in the movable portion, are effectively dissipated, especially when airflow is guided along the exterior of the base member. Furthermore, the base member can be produced by die casting or injection molding, which is cost-effective.

[0057] Typically, the movable and stationary parts can be arranged with significant or even complete overlap to limit the size and size-related costs of the inductive power transfer board. Therefore, when viewed along the axis of motion of the movable part, even in the retracted state, the movable part and the stationary part can be arranged above each other, but not necessarily adjacent to each other. Furthermore, in the retracted state, the movable part can serve as a cover for the stationary part or, as discussed herein, a cover component. This helps protect the stationary part or cover component from damage and offers the potential for cost savings, as it reduces the design requirements for the durability of the assembly.

[0058] For example, according to one aspect, the area covered by the movable part is at least 80% of the area covered by the fixed part. This area may involve a region in a horizontal spatial plane and / or in a plane extending perpendicularly to the direction of movement of the movable part. In this way, at least partial overlap between the movable part and the moving part can be achieved.

[0059] Additionally or alternatively, the coverage area of ​​the movable part is at least as large as the coverage area of ​​the fixed part, or its size is at least 80% of the size of the coverage area of ​​the fixed part. Furthermore, when projected onto a horizontal spatial plane and / or a plane extending perpendicularly to the direction of movement of the movable part, the coverage area may be related to the shape or perimeter of the relevant part.

[0060] According to another aspect, the space between the movable part and the fixed part is at least partially surrounded by the cover member. This space can define a volume between the movable part and the fixed part that increases and decreases as the movable part moves relative to the fixed part (e.g., it is maximum in the extended state of the movable part and minimum in the retracted state of the movable part).

[0061] The space may be cylindrical, and at least a portion of the fixed and movable portions may be defined by or extend parallel to a reference plane of the cylindrical space. A cover member may define or restrict the side surfaces or shell surfaces of the cylindrical space. Typically, the cover member may surround the space on four sides.

[0062] Inverters, any other heat sources, any electrical components, and / or at least a portion of the primary winding structure may be positioned within or above the space. In other words, they may be configured to at least partially overlap with the space or at least overlap with the covered area of ​​the space (e.g., when viewed from above). In particular, any of the components may be positioned within the (virtual) space when viewed along the axis of motion of the movable portion and / or when the shell surface of the space is virtually extended beyond the cover member (e.g., along the axis of motion).

[0063] The cover component may include holes, such as holes for guiding cables for connecting to an external power source through them. However, the cover component has a surface that is preferably mostly closed or even completely closed (e.g., where the size of the potential holes is less than 5% of the total area of ​​the cover component).

[0064] The cover member can be made of flexible or elastic materials, including, for example, elastic materials such as rubber or plastic. It may include folding or other predetermined deformable portions. In one example, the cover member is a foldable bellows that folds and unfolds according to the movement of movable portions.

[0065] According to another embodiment, the inverter is positioned closer to the movable portion on the lower side facing the space surrounded by the cover member (or facing the fixed portion), and then extends to the upper side of the movable portion facing the surrounding environment. This is advantageous in terms of thermal management, as the generated heat can be conducted into and dissipated from the space, for example, through the airflow generating unit discussed herein. Moreover, this allows for efficient arrangement of the space. Typically, the inverter is preferably placed below and preferably overlaps with the primary winding structure (i.e., the inverter and the primary winding structure are stacked on top of each other).

[0066] In one example, the airflow generating unit is positioned on the lower side of the movable portion facing the fixed portion and / or in the space surrounded by the cover member (e.g., on the lower side of the base member of the movable portion). Specifically, the airflow generating unit may be placed within the space surrounded by the cover member. Alternatively or additionally, the airflow generating unit is positioned closer to said lower side and then extends to the upper side of the movable portion facing the surrounding environment. Since heat sources such as inverters are typically preferably placed below the primary winding structure and therefore close to said lower side, the above-described placement of the airflow generating unit enables effective heat dissipation.

[0067] According to another aspect, cables for supplying power from an external power source to the movable part can be connected to or attached to the movable part within the space. In other words, the cables can be guided from the area surrounding the inductive power transmission board into the space and then connected to the movable part (e.g., to its connection terminals) within the space. Therefore, this connection to the movable part can be at least partially surrounded by a cover member, which reduces the requirements for additional sealing. As previously mentioned, the cover member may include predetermined openings for guiding the cables through it.

[0068] For example, an inductive power transmission plate (e.g., a fixed portion or a gap formed between the fixed portion and the cover member), particularly the cover member, may include at least two openings or two predetermined openable portions (e.g., including a removable cover or locally lower material strength) for guiding cables to the external power source. Therefore, the user can decide how the cable should be positioned relative to the inductive power transmission plate. Typically, multiple openings or openable portions can be placed at a distance from each other or on different sides of the inductive power transmission plate. For example, the openings or openable portions can be positioned such that the cable can be positioned on different sides of the inductive power transmission plate, such as on the front or back of the inductive power transmission plate. This increases the installation flexibility of the inductive power transmission plate. Furthermore, this helps to avoid guiding the cable in a way that would require the vehicle to be driven through (i.e., driven and squeezed) when positioned above the inductive power transmission plate.

[0069] Typically, the movable portion can house or encapsulate the inverter and primary winding structure, sealing them from the surrounding environment, particularly in a waterproof manner. In known solutions, separate housings and separate seals must be provided for the electrical components positioned in the fixed and movable portions. This application reduces manufacturing effort and associated costs compared to known solutions. Conversely, with the solution disclosed herein, the number of parts, housing portions, and / or the number or length of required seals, as well as the associated manufacturing and assembly steps, can be reduced.

[0070] As described above, the inductive power transmission board may also include at least one of the following: - At least one air inlet (e.g., in the cover member discussed herein, or in an opening or gap in or below a fixed portion), through which the airflow generating unit draws in air from the surroundings; and - At least one air outlet (e.g., in the cover member discussed herein or in an opening or gap in or below the fixed part) through which air from the airflow generated by the airflow generating unit can escape into the surrounding environment.

[0071] Furthermore, a method for manufacturing an inductive power transmission plate is proposed, particularly for a power transmission plate of a system for transmitting inductive power to a vehicle. The inductive power transmission plate includes a fixed portion and a movable portion, wherein the movable portion can move between a retracted state and an extended state. The method includes:

[0072] A primary winding structure and at least one inverter electrically connected to the primary winding structure are provided in the movable part.

[0073] The method may include any further steps, any improvements, or any further features to provide any previously or subsequently discussed interactions, operating states, or functions, and to provide or integrate any further components of the inductive power transfer board. Specifically, any previous or subsequent interpretations and improvements regarding device features may also apply to equivalent method features. Generally, the method may include manufacturing the inductive power transfer board according to any of the foregoing or subsequent aspects. Attached Figure Description

[0074] In the following description, embodiments of the invention will be illustrated with reference to the accompanying schematic diagrams. Features that correspond to each other in type and / or function may be assigned the same reference numerals in all the drawings. In these drawings:

[0075] Figure 1 An inductive power transmission board according to an embodiment of the present invention is shown, which has been manufactured using a method according to an embodiment of the present invention and is in a retracted state;

[0076] Figure 2 yes Figure 1 A schematic diagram of an inductive power transmission plate in an extended state.

[0077] Figures 3A-3B It shows along Figure 1 ( Figure 3B )and Figure 2 ( Figure 3A The cross section of the first axis AA; and

[0078] Figures 4A-4B It shows along Figure 1 ( Figure 3B )and Figure 2 ( Figure 3A The cross section of the second axis BB. Detailed Implementation

[0079] exist Figure 1 The diagram shows an inductive power transfer plate 10, which may also be referred to simply as plate 10 below. Plate 10 includes a movable portion 12 that is movable relative to the ground, and a stationary (i.e., immovable) portion 14 of plate 10, which is mostly covered, lies on the ground. In the illustrated state, the movable portion 12 is in a retracted state. The inductive power transfer plate 10 thus extends largely parallel to the horizontal plane of space.

[0080] On the contrary, Figure 2 In the diagram, the movable part 12 is shown in an extended state. For this purpose, it moves (i.e., rises) along a movement axis M that coincides with the vertical spatial axis via an actuator discussed below. A movement in the opposite direction along the movement axis M results in a return. Figure 1 The retracted state is shown in the image.

[0081] As can be seen, the movable part 12 and the fixed part 14 are connected to each other by a cover member 16. The cover member 16 is configured as a foldable bellows that folds and unfolds according to the movement of the movable part 12. The cover member 16 defines the space between the movable part 12 and the fixed part 14, which will be discussed in more detail below.

[0082] Cover member 16 includes an orientation located on plate 10 Figure 2 An opening 18 is located on the observer's side. Through this opening 18, a cable 20 (e.g., a grid cable) can be routed to a connection to an external power source (not shown), such as a public power grid. The cable 20 is the sole connection between the board 10 and the external power source. Figure 2 As shown at the top, the cable 20 can also be guided from the plate 10 to the external power source in different directions. For this purpose, a similar opening 18 is provided on the opposite side of the cover member 16.

[0083] The two openings 18 are present when the board 10 is delivered to the customer, or they can be opened manually due to the presence of removable covers or the limited strength of the material, which is easily punctured. Therefore, the customer has at least two options for guiding the cable 20 toward the external power source. This allows him to position the cable 20 according to local conditions, and in particular, it eliminates the need to drive the vehicle over the cable 20 (e.g., approaching the board 10 from the side away from the cable 20 and then driving backwards as he leaves the board 10).

[0084] Similarly, an opening or an openable portion can be provided in the fixed portion to replace the opening 18 in the cover member 16. Likewise, a gap can be provided between the cover member 14 and the fixed portion and used as a corresponding opening.

[0085] The cross-sectional view based on axis AA will be discussed below. Figure 3A and 3B They will be discussed together below, although some figure labels may be provided in only one of these figures rather than both, showing cross sections according to axis AA. Figure 3A Showing Figure 2 The state of elevation or extension. Figure 3B Showing Figure 1 The retracted state.

[0086] As a standard and known component of the inductive power transmission plate 10, an actuator 11 in the form of an electrically driven telescopic cylinder is shown, which causes the movable part 12 to move up and down relative to the fixed part 14. Furthermore, a guide device 13, or in other words, a mechanical structure supporting said movement, is provided in the form of two standard scissor-leg mechanisms 13.

[0087] Furthermore, the fixed portion 14 is configured as a frame-like member with a central opening 21 for connecting the space 50, discussed below, to the surrounding environment. The fixed portion 14 does not contain any electrical components and has no electrical connection to the movable portion 12. However, the actuator 11 is fixed to both parts of the fixed portion 14 and mechanically rests against the fixed portion 14 when the movable portion 12 is pushed upwards or pulled downwards. Compared to known solutions, the fixed portion 14 is considerably smaller and cheaper to manufacture due to its smaller size, large opening 21, and simple, frame-like design.

[0088] The movable portion 12 includes a base member 22 made of metallic material, and in the case shown, of aluminum. The base member 22 is preferably manufactured by die casting. It is typically configured as a flat plate member (i.e., not a perfectly defined plane) with some recesses, protrusions, overhangs, etc. The underside of the base member 22 faces the fixed portion 12 and forms the underside of the entire movable portion 12.

[0089] The area or coverage area A1 covered by the base member 22 and the movable member 12 extends beyond the corresponding area or coverage area A2 of the fixed part 14. In other words, the base member 22 and the movable member 12 completely cover the fixed part 14. This is advantageous, for example, because it helps the fixed part 14 and the cover member 16 to be protected from environmental influences by the base member 22, especially when the base member is in the retracted state.

[0090] A cable carrier element 24 made of plastic material is placed on top of the base member 22. The cable carrier element 24 includes a recess in which the phase wire of the primary winding structure 26 is positioned in a commonly known manner. The configuration of the cable carrier element 24 and the primary winding structure 26 is not the focus of this solution and can be implemented according to known solutions. This also involves a standard ferrite element 28 disposed on the lower side of the primary winding structure 26. Furthermore, a foreign object detection system (not specifically shown) may be included, and a known detection winding may be included. The cable carrier element 24 is covered by a flat cover member 30 forming the movable portion 12 and the upper side of the plate 10.

[0091] The cable carrier element 24 is placed on and covers the upper side of the base member 22. Preferably, the seal 30 is placed between the cable carrier element 24 and the base member 22.

[0092] Returning to the base member 22, an electrical component group 32 is shown, for example, an electrical component group 32. This includes power electronic devices with pads 10, and at least one of them includes an inverter 34 for energizing the primary winding structure 26 disposed at the base member 22. More specifically, they are disposed on the side facing the cable-carrying element 24, i.e., on the upper side of the base member 22.

[0093] By way of example only, the base member 22 of the illustrated embodiment includes a recess 36 in which electrical components 32 are placed such that they are at least partially surrounded on five sides. As a further optional but preferred measure, the open sides of the recess 36 are at least partially covered by a shielding element 38 configured to electromagnetically shield the primary winding structure 26 and the electrical components 32 from each other.

[0094] from Figure 3B As can be clearly seen in the retracted state, the recess 36 offers advantages in terms of space efficiency. For example, the dimensions of the recess 36 can be similar to the height of the actuator 11 and / or guide device 13 in the retracted state, both of which can be more or less fixed or immutable in size. Therefore, the electrical components, particularly the recess 36, do not significantly increase the overall height of the power transmission plate 10, but rather utilize the space available due to the minimum height defined by the mechanical structure of the plate 10.

[0095] Overall, the electrical components 32, particularly the inverter 34 and the primary winding structure 26, are housed within the movable part 12 and are preferably encapsulated therein in a waterproof manner.

[0096] The electrical connections (e.g., cables) between electrical components 32, particularly the inverter 34 and the primary winding structure 26, are not specifically shown, but these connections have a reduced length. Furthermore, since the inverter 34 and the primary winding structure 26 are both located within the movable portion 12, these interconnected components cannot move relative to each other, thus the cables experience almost no movement. In particular, they are not frequently lifted, unrolled, etc. This reduces the risk of cable breakage.

[0097] Another advantage is the improved thermal management of plate 10. For example, any electrical component 32 could potentially act as a heat source. However, they are placed close, and practically directly, to the underside of the base member 22. Specifically, they are closer to this underside than to the upper side of the movable part 12. In other words, when along… Figure 2 When viewed from the moving axis M, the electrical components 32, particularly the inverter 34, are located between the base member 22 (or at least the lower side) and the primary winding structure 26.

[0098] Therefore, the heat generated by the electrical component 32 can be conducted through the metal base member 22, particularly through the underside of the base member 22, to the space 50 between the movable part 12 and the fixed part 14, which is surrounded by the cover member 16. From there, as... Figures 4A-4B Further discussion suggests that heat can be delivered to the surrounding environment by an airflow generating unit 52 (e.g., in the form of an electric fan).

[0099] exist Figure 3A In the middle, the cable 20 connected to the external power supply can be seen again. Specifically, it can be seen that it passes through opening 18 (this opening is not in...). Figure 2 The visible opening 18 is not directly connected to the space 50; another opening 18 is located on the opposite side of the plate 10. Furthermore, it can be seen that the cable 20 is connected to the movable part 12, and more specifically, to the connection terminal 54 via the space 50. Electrical components 32, particularly the inverter 34, are connected to said connection terminal 54 (not specifically described). Therefore, electrical energy can be supplied from an external power source to the electrical components 32, particularly the inverter 34, which in turn energizes the primary winding structure 26. Conversely, no power from an external power source is supplied to the fixed part 14, and no electrical connection is formed between the cable 20 and the fixed part 14, or between the movable part and the fixed part.

[0100] exist Figure 4A , 4B In the middle, it is shown that according to Figure 1 A cross-sectional view of plate 10 taken along axis BB. Figure 4A In the image, the scissor-shaped guide device 13 can be seen again. Furthermore, as previously described, two possible methods for setting the cable 20 are shown.

[0101] exist Figure 4A , 4B It can also be seen that the fan 52 is positioned on the lower edge of the base member 22 and is generally offset from the center of the base member 22. This allows the airflow, indicated by the small arrows, to be guided along the substantial length of the base member 22, thereby dissipating a considerable amount of heat. Specifically, the airflow shown can be guided through a channel formed by and located between the recesses 36, thus very close to the surface of the base member 22 adjacent to the heat source formed by the electrical component 32.

[0102] It should be noted that the recess 36 forms a protrusion on the underside of the base member. Figures 3A-3B As can be seen, these protruding, facing outer walls 82 thus define the sidewalls of the channels through which airflow can be guided.

[0103] As in Figure 4B More specifically, the air inlet 23 is in the form of a gap, opening at the lower side of the fixed portion 14, through which the fan 52 draws in air from the external environment. Furthermore, an air outlet 25 is provided, through which the heated air can be conducted back to the external environment.

[0104] It should be noted that, as a general aspect of the invention, which is not limited to the embodiments, one of the openings 18 that can (optionally) guide the cable 20 through can also be used as an air outlet or air inlet, for example by designing at least one of the multiple openings 18 to have a correspondingly large cross-sectional dimension, so that after the cable 20 passes through the opening 18, there is still a gap for controlled flow.

[0105] As an optional feature, in Figure 4B The diagram illustrates a cooling structure 80 for expanding the surface area of ​​the base member 22, and particularly the surface area of ​​the lower side of the base member 22. The cooling structure 80 may, for example, be a heat sink or heat fin. This further aids in heat dissipation when airflow is guided along the cooling structure 80.

Claims

1. An inductive power transmission plate (10), comprising a fixed portion (14) and a movable portion (12), wherein the movable portion (12) is movable between a retracted state and an extended state, characterized in that, The movable part (12) also includes a primary winding structure (26) and at least one inverter (34) electrically connected to the primary winding structure (26). The movable part (12) also includes a connection terminal and / or a connection cable for connecting to an external power source; The inductive power transmission plate (10) further includes an actuator (11) for moving the movable part (12), wherein the actuator (11) is electrically connected to the movable part (12), and the movable part (12) is used to provide the actuator (11) with electrical energy from the external power source. The actuator (11) causes the entire movable part (12) to move as a whole in the vertical direction.

2. The inductive power transmission plate (10) according to claim 1, characterized in that, There is no electrical connection between the movable part (12) and the fixed part (14).

3. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The fixed portion (14) has no electrical components (32), which include electrical components for energizing the primary winding structure (26).

4. The inductive power transmission plate (10) according to claim 1, characterized in that, The actuator (11) mechanically abuts against the fixed part (14).

5. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The inductive power transmission plate (10) further includes an airflow generating unit (52), which is electrically connected to the movable part (12).

6. The inductive power transmission plate (10) according to claim 5, characterized in that, The movable part (12) includes a connection terminal (54) for connecting to an external power source and / or a connection cable (20), and the movable part (12) provides electrical energy from the external power source to the airflow generating unit (52).

7. The inductive power transmission plate (10) according to claim 5, characterized in that, The airflow generating unit (52) is located at or within the movable part (12).

8. The inductive power transmission plate (10) according to claim 5, characterized in that, The airflow generating unit (52) is used to generate an airflow from the surrounding environment and flow along the movable part (12) and / or within the movable part (12).

9. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The movable part (12) includes a base member (22) that supports the primary winding structure (26) and the inverter (34).

10. The inductive power transmission plate (10) according to claim 9, characterized in that, The inverter (34) is at least partially positioned between the base member (22) and the primary winding structure (26), wherein, when viewed along the axis of motion (M) of the movable portion (12), it is at least partially positioned between the base member (22) and the primary winding structure (26).

11. The inductive power transmission plate (10) according to claim 9, characterized in that, The inverter (34) is at least partially disposed in a recess (36) within the base member (22).

12. The inductive power transmission plate (10) according to claim 9, characterized in that, The base component (22) is made of metal.

13. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The area covered by the movable part (12) is at least 80% of the area covered by the fixed part (14).

14. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The coverage area of ​​the movable part (12) is at least as large as the coverage area of ​​the fixed part (14).

15. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The space (50) between the movable part (12) and the fixed part (14) is at least partially surrounded by the cover member (16).

16. The inductive power transmission plate (10) according to claim 15, characterized in that, Compared to the upper part of the movable part (12) facing the surrounding environment, the inverter (34) is located on the lower side of the movable part (12) facing the space (50) surrounded by the cover member (16).

17. The inductive power transmission plate (10) according to claim 16, characterized in that, The space (50) between the movable part (12) and the fixed part (14) is at least partially surrounded by the cover member (16), and the airflow generating unit (52) is located on the lower side of the movable part (12) facing the space (50) surrounded by the cover member (16), and / or one end of the airflow generating unit (52) is located closer to the lower side of the movable part (12), and the other end extends to the upper side of the movable part (12) facing the surrounding environment.

18. The inductive power transmission plate (10) according to claim 16, characterized in that, The space (50) between the movable part (12) and the fixed part (14) is at least partially surrounded by the cover member (16), and a cable (20) for supplying power from an external power source to the movable part (12) is used to connect to the movable part (12) within the space (50).

19. The inductive power transmission plate (10) according to claim 18, characterized in that, The inductive power transmission board (10) includes at least two openings (18), each opening for guiding a cable (20) to the external power source.

20. The inductive power transmission plate (10) according to claim 19, characterized in that, The movable part (12) houses the inverter (34) and the primary winding structure (26) and seals them from the surrounding environment.

21. The inductive power transmission plate (10) according to claim 5, characterized in that, The inductive power transfer plate (10) includes at least one of the following: At least one air inlet (23), through which an airflow generating unit (52) draws in ambient air; and At least one air outlet (25) is provided for air from the airflow generated by the airflow generating unit (52) to escape into the surrounding environment.

22. The inductive power transmission plate (10) according to claim 1 or 2, characterized in that, The power transmission board (10) is a power transmission board (10) of a system for transmitting induced electrical energy to the vehicle.

23. A method for manufacturing an inductive power transmission plate (10), the inductive power transmission plate (10) comprising a fixed portion (14) and a movable portion (12), wherein, The movable portion (12) is designed to be movably in a retracted state or an extended state, characterized in that the method comprises: A primary winding structure (26) and at least one inverter (34) electrically connected to the primary winding structure (26) are provided in the movable part (12); Provides connection terminals and / or connection cables for connecting to an external power source; An actuator (11) is provided for moving the movable part (12); wherein the actuator (11) causes the entire movable part (12) to move as a whole in the vertical direction; The actuator (11) is electrically connected to the movable part (12), and the movable part (12) is used to provide the actuator (11) with electrical energy from the external power source.

24. The method according to claim 23, characterized in that, The inductive power transmission board (10) is a power transmission board (10) for a system that transmits inductive power to the vehicle.

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