Onboard charging device for electric vehicles and system and method for wireless charging of electric vehicles

Abstract

An on-board charging device for an electric vehicle includes: a mains input including a power factor correction converter; a mains-side DC / AC converter; a transformer having a mains-side coil and a battery-side coil; a battery-side AC / DC converter; a battery connector; one or more bypass switches for electrically connecting the mains-side DC / AC converter to the battery-side AC / DC converter when closed. The transformer is configured to magnetically couple to a TX pad of an external wireless power transmitter such that the mains-side coil and the battery-side coil receive power. When the bypass switches are closed and the transformer is magnetically coupled to the external wireless power transmitter, power is transferred to the battery connector through the battery-side AC / DC converter and the mains-side DC / AC converter. The on-board charging device exhibits higher power density at a significantly reduced cost.

Description

Technical Field

[0001] This invention generally relates to the field of electric vehicles, and more specifically, to electric vehicles, on-board charging (OBC) devices for electric vehicles, and systems and methods for wirelessly charging electric vehicles. Background Technology

[0002] Current electric vehicle (EV) charging technologies can generally be categorized into on-board charging (OBC), off-board charging, and wireless charging (WC). In many respects, the topologies currently used in one or more conventional OBC and WC systems are very similar. To some extent, one could say that conventional WC is a conventional OBC with a loosely coupled insulated transformer. This integration is preferred because it can partially improve power density and partially reduce the overall cost of both conventional OBC and WC systems.

[0003] Currently, several methods have been proposed for integrating OBC and WC. One proposed method is a traditional direct current (DC) link sharing approach for integrating traditional OBC and WC. In this method, both the traditional OBC and WC are connected at the DC link level, resulting in very low integration and an increased number of required components. However, this method does not require reconfigurable switches. Another proposed method is a traditional power factor correction (PFC) level connection approach for integrating traditional OBC and WC. The traditional WC is integrated at the PFC level. With traditional WC, power is processed through several stages, leading to reduced efficiency. Furthermore, this PFC level connection method does not reuse traditional AC-DC or DC-AC converters, increasing the number of required components and further contributing to low integration.

[0004] Subsequently, different methods for integrating traditional OBCs and traditional WCs using conventional AC / DC converters with or without switches were proposed. In the conventional connection method at an AC / DC converter with switches, the AC / DC (e.g., diode bridge) stage is common in both the conventional WC and conventional OBC systems. In this method, relays and connectors are used to isolate the conventional OBC and conventional WC during operation. In the conventional connection method at an AC / DC converter without switches, one of the AC / DC stages is common in both the conventional WC and conventional OBC systems. However, the conventional connection method at an AC / DC converter without switches does not require reconfiguration of the switches. Therefore, magnetic integration of the conventional WC and conventional OBC systems is not provided. Based on this, a conventional magnetic integration method for magnetically integrating a conventional WC with a conventional OBC is also proposed. In this conventional magnetic integration method, the conventional WC pad is used as the transformer of the conventional OBC system. The conventional magnetic integration method requires additional resonant elements (e.g., external inductors, external capacitors, and two AC switches) to isolate the OBC. Conventional connection methods and conventional magnetic integration methods at AC / DC converters without switches reuse only one of the two AC / DC converters in a conventional OBC, resulting in reduced rated power, power density, and utilization. Therefore, there is a technical problem of low system integration efficiency in both conventional WC and conventional OBC systems.

[0005] Therefore, based on the above discussion, it is necessary to overcome the aforementioned drawbacks associated with traditional integration methods for traditional WC and traditional OBC systems. Summary of the Invention

[0006] This invention provides an electric vehicle, an on-board charging (OBC) device for the electric vehicle, and a system and method for wirelessly charging the electric vehicle. This invention provides a solution to the problem of low integration efficiency in conventional wireless charging (WC) and conventional OBC systems. The object of this invention is to provide a solution that at least partially solves the problems encountered in the prior art, and to provide an electric vehicle, an improved on-board charging (OBC) device for the electric vehicle, and a system and method for wirelessly charging the electric vehicle.

[0007] One or more objects of the invention are achieved by means of the solutions provided in the appended independent claims. Advantageous embodiments of the invention are further defined in the dependent claims.

[0008] In one aspect, the present invention provides an on-board charging (OBC) device for an electric vehicle, comprising: a mains input terminal including a power factor correction (PFC) converter; a mains-side DC / AC converter; a transformer having a mains-side coil and a battery-side coil; a battery-side AC / DC converter; a battery connector; and one or more bypass switches for electrically connecting the mains-side DC / AC converter to the battery-side AC / DC converter when closed. The transformer is used for magnetic coupling to the TX pad of an external wireless power transmitter (WPT), such that the mains-side coil and the battery-side coil receive electrical energy. When the bypass switch is closed and the transformer is magnetically coupled to the external wireless power transmitter, electrical energy is transmitted to the battery connector through the battery-side AC / DC converter and the mains-side DC / AC converter.

[0009] This invention provides an improved OBC device for use as the stated OBC device, and a wireless charger (or wireless charging device) for wirelessly charging the electric vehicle. The disclosed OBC device is used to operate at two independent frequencies based on the AC input and the external wireless power transmitter. The disclosed OBC device exhibits higher power density at a significantly reduced cost. In addition to two standard resonant capacitors, the disclosed OBC device requires no additional resonant elements (e.g., inductors or capacitors).

[0010] In one implementation, the OBC device further includes: a mains-side resonant slot having a first capacitor and a first inductor; and a battery-side resonant slot having a second capacitor and a second inductor; wherein, the values ​​of the first capacitor and the first inductor of the mains-side resonant slot are selected to enable the OBC device to operate through the mains input terminal; and the values ​​of the second capacitor and the second inductor of the battery-side resonant slot are selected to enable the OBC device to operate through the external wireless power transmitter.

[0011] By selecting the values ​​of the first capacitor and the first inductor in the AC side resonant slot, the OBC device is made to operate through the AC input terminal; by selecting the values ​​of the second capacitor and the second inductor in the battery side resonant slot, the OBC device is made to operate through the external WPT.

[0012] In another implementation, the values ​​of the first capacitor and the first inductor of the AC side resonant slot are selected to correspond to the first resonant frequency when the OBC device operates through the AC input terminal; the values ​​of the second capacitor and the second inductor of the battery side resonant slot are selected to correspond to the second resonant frequency when the OBC device operates through the external wireless power transmitter.

[0013] By selecting the values ​​of the first capacitor and the first inductor of the AC side resonant slot, the first resonant frequency of the OBC device when operating through the AC input terminal can be defined; by selecting the values ​​of the second capacitor and the second inductor of the battery side resonant slot, the second resonant frequency of the OBC device when operating through the external WPT can be defined.

[0014] In another implementation, the transformer is used to operate via the mains input at a first resonant frequency in the range of 200 kHz to 600 kHz (or higher), and via the external wireless power transmitter at a second resonant frequency in the range of 80 kHz to 90 kHz.

[0015] The transformer is designed to operate at two independent frequencies without requiring any additional resonant elements. The two independent frequencies are the first resonant frequency and the second resonant frequency.

[0016] In another implementation, the mains-side resonant slot includes a first capacitor for generating the first capacitance, and the battery-side resonant slot includes a second capacitor for generating the second capacitance.

[0017] Using the first capacitor to generate the first capacitance and using the second capacitor to generate the second capacitance simplifies the structure of the OBC device.

[0018] In another implementation, the mains-side coil and the battery-side coil are configured to overlap in offset order to simultaneously generate the first inductance of the mains-side resonant slot and the second inductance of the battery-side resonant slot.

[0019] Because of the offset overlap between the AC side coil and the battery side coil, the OBC device exhibits both the first inductance and the second inductance; thus, the OBC device does not require additional magnetic components.

[0020] In another implementation, the bypass switch is a DC switch.

[0021] Using the bypass switch as the DC switch can reduce the cost of the OBC device.

[0022] In another implementation, each of the AC / DC converter on the mains side and the AC / DC converter on the battery side is a full-bridge converter, a half-bridge converter, or a diode bridge converter.

[0023] Using the AC / DC converter on the mains side and the AC / DC converter on the battery side as the full-bridge converter, the half-bridge converter, and the diode bridge converter can efficiently convert electrical energy from the DC domain to the AC domain and vice versa.

[0024] In another aspect, the present invention provides an electric vehicle comprising at least one battery and an on-board charging (OBC) device.

[0025] The electric vehicle achieves all the advantages and effects of the OBC device provided by this invention.

[0026] In another aspect, the present invention provides a system for wirelessly charging an electric vehicle, the system comprising: the electric vehicle; and an external wireless power transmitter (WPT) including a TX pad for transmitting wireless power to the transformer of the OBC device in the electric vehicle.

[0027] The system for wirelessly charging the electric vehicle has all the advantages and effects of the OBC device and the electric vehicle provided by this invention. The system improves power density and copper utilization, and reduces current stress and losses.

[0028] In another aspect, the present invention provides a method for charging an electric vehicle, the method comprising: magnetically coupling the transformer to the TX pad of an external wireless power transmitter (WPT) such that the AC side coil and the battery side coil receive electrical energy; closing the one or more bypass switches to electrically connect the AC side DC / AC converter to the battery side AC / DC converter, thereby transmitting electrical energy to the battery connector through the battery side AC / DC converter and the AC side DC / AC converter.

[0029] The disclosed method provides bidirectional power flow and enables the electric vehicle to exhibit high power density at a reduced cost.

[0030] In another aspect, the present invention provides a method for charging the electric vehicle, the method comprising: connecting the mains input terminal to an external mains power source; disconnecting the one or more bypass switches to disconnect the electrical connection between the mains-side DC / AC converter and the battery-side AC / DC converter, thereby transferring electrical energy to the mains-side coil of the transformer.

[0031] The disclosed method is used for on-board charging of the electric vehicle.

[0032] It should be understood that all of the above implementation methods can be combined.

[0033] It should be noted that all devices, elements, circuits, units, and apparatuses described in this invention can be implemented as software or hardware elements or any combination thereof. All steps performed by the various entities described in this application, and the functions described as being performed by the various entities, are intended to indicate that the respective entities are suitable for or used to perform the respective steps and functions. Although in the following detailed description of specific embodiments, a particular function or step performed by an external entity is not reflected in the detailed description of the specific element of the entity performing that particular step or function, it should be apparent to those skilled in the art that these methods and functions can be implemented in the corresponding hardware or software elements or any combination thereof. It should be understood that various combinations of the features of this invention can be made without departing from the scope of the invention as defined in the appended claims.

[0034] Additional aspects, advantages, features and objects of the invention will become apparent from the accompanying drawings and the detailed description of illustrative implementations as explained in conjunction with the following appended claims. Attached Figure Description

[0035] A better understanding of the above overview and the following detailed description of illustrative embodiments can be obtained by reading the accompanying drawings. Exemplary structures of the invention are shown in the drawings to illustrate the invention. However, the invention is not limited to the specific methods and tools disclosed herein. Furthermore, those skilled in the art will understand that the drawings are not drawn to scale. Where possible, the same elements are represented by the same numbers.

[0036] Embodiments of the invention will now be described by way of example only with reference to the following accompanying drawings, in which:

[0037] Figure 1 A block diagram of various exemplary elements of an on-board charging (OBC) device for electric vehicles provided in an example of the present invention is shown;

[0038] Figure 2 A block diagram illustrating various exemplary components of an electric vehicle provided in one example of the present invention is shown;

[0039] Figure 3 A block diagram of various exemplary components of a system for wirelessly charging an electric vehicle is shown as an example of the present invention;

[0040] Figure 4 A circuit diagram of a system provided by an example of the present invention is shown, in which an on-board charging (OBC) device is shown operating via an AC power input and an external wireless power transmitter (WPT);

[0041] Figure 5A A schematic diagram of the coil structure of the transformer in an OBC device provided by an example of the present invention is shown;

[0042] Figure 5B A graphical representation of the change in the ratio between leakage inductance and magnetizing inductance as the overlap between the two coils of the transformer in an OBC device increases, provided by an example of the present invention, is shown.

[0043] Figure 6 A block diagram of various exemplary components of a system for wirelessly charging an electric vehicle is shown as an example of the present invention;

[0044] Figure 7 A circuit diagram of a system for operation as an OBC device is shown as an example of the present invention;

[0045] Figure 8A A graphical representation of the voltage waveform of an OBC device provided by an example of the present invention at a sub-resonant frequency is shown;

[0046] Figure 8B A graphical representation of the current waveform of an OBC device provided by an example of the present invention at a sub-resonant frequency is shown;

[0047] Figure 8C A graphical representation of the voltage waveform of an OBC device provided by an example of the present invention at the resonant frequency is shown;

[0048] Figure 8D A graphical representation of the current waveform of an OBC device provided by an example of the present invention at the resonant frequency is shown;

[0049] Figure 9 A circuit diagram of a system provided by an example of the present invention for use as a wireless charger (WC) is shown.

[0050] Figure 10A A graphical representation of the voltage waveform of WC at the resonant frequency provided in an example of the present invention is shown;

[0051] Figure 10B A graphical representation of the current waveform of WC at the resonant frequency provided by an example of the present invention is shown;

[0052] Figure 11A A schematic diagram of the coil structure of the transformer in an OBC device provided by an example of the present invention is shown;

[0053] Figure 11B A graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in an example of the present invention is shown;

[0054] Figure 12A A schematic diagram of the transformer coil structure of an OBC device provided in another example of the present invention is shown;

[0055] Figure 12B A graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in another example of the present invention is shown;

[0056] Figure 13A A schematic diagram of the transformer coil structure of an OBC device provided in yet another example of the present invention is shown;

[0057] Figure 13B A graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in yet another example of the present invention is shown;

[0058] Figure 14 A flowchart illustrating an example of a method for charging an electric vehicle provided by the present invention is shown.

[0059] Figure 15 A flowchart of a method for charging an electric vehicle is shown as another example of the present invention.

[0060] In the accompanying diagram, underlined numbers indicate the item to which the underlined number is located or the item adjacent to the underlined number. Ununderlined numbers refer to the items identified by the line connecting the ununderlined number to the item. When a number is ununderlined and has an associated arrow, the ununderlined number identifies the general item that the arrow points to. Detailed Implementation

[0061] The following detailed description illustrates embodiments of the present invention and ways in which these embodiments can be implemented. Although some modes of implementing the invention have been disclosed, those skilled in the art will recognize that other embodiments for implementing or carrying out the invention may also exist.

[0062] Figure 1A block diagram illustrating various exemplary components of an on-board charging (OBC) device for electric vehicles according to an embodiment of the present invention is shown. Reference Figure 1 The figure shows a block diagram 100 of an on-board charging (OBC) device 102 including an AC input terminal 104, an AC-side DC / AC converter 106, a transformer 108, a battery-side AC / DC converter 110, a battery connector 112, one or more bypass switches 114, an AC-side resonant slot 116, and a battery-side resonant slot 118. Figure 1 Further shown is an external wireless power transmitter (WPT) 120 including a transmitter (TX) pad 120A. The AC input 104 includes a power factor correction (PFC) converter 104A. A transformer 108 includes an AC-side coil 108A and a battery-side coil 108B. An AC-side resonant slot 116 includes a first capacitor 116A, and a battery-side resonant slot 118 includes a second capacitor 118A.

[0063] An on-board charging (OBC) device 102 for electric vehicles includes:

[0064] The mains input terminal 104 includes a power factor correction (PFC) converter 104A;

[0065] 106 DC / AC converter on the mains side;

[0066] Transformer 108 has a mains-side coil 108A and a battery-side coil 108B;

[0067] Battery-side AC / DC converter 110;

[0068] Battery connector 112;

[0069] One or more bypass switches 114 are used to electrically connect the AC-side converter (i.e., AC-side DC / AC converter 106) to the battery-side converter (i.e., battery-side AC / DC converter 110) when closed.

[0070] Among them, transformer 108 is used for magnetic coupling to TX pad 120A of external wireless power transmitter (WPT) 120, so that mains side coil 108A and battery side coil 108B receive electrical energy.

[0071] When the bypass switch 114 is closed and the transformer 108 is magnetically coupled to the WPT 120, electrical energy is transmitted to the battery connector 112 through the battery-side converter (i.e., the battery-side AC / DC converter 110) and the mains-side converter (i.e., the mains-side DC / AC converter 106).

[0072] OBC device 102 includes appropriate logic, circuitry, interfaces, or code for use in an electric vehicle to charge a battery via battery connector 112. OBC device 102 operates via AC input 104 and an external WPT (or simply WPT) 120. When one or more bypass switches 114 are open, OBC device 102 operates via AC input 104 and charges the battery via battery connector 112. When one or more bypass switches 114 are closed, OBC device 102 operates via WPT 120 and charges the battery via battery connector 112 based on electrical energy received from WPT 120. For example, Figure 4 The text describes in more detail the operation of the OBC device 102 via the mains input terminal 104 and the WPT 120.

[0073] The AC input terminal 104 includes appropriate logic, circuitry, interfaces, or code for providing direct current (DC) power at the output. The AC input terminal 104 may be the power grid.

[0074] PFC converter 104A includes appropriate logic, circuitry, interface, or code for adjusting the power factor of the DC power supplied by AC input 104. Typically, a PFC converter is used to bring the power factor of the DC power supply closer to 1. In other words, a PFC converter is used to bring the power factor angle (or phase angle) of the DC power supply closer to 0°, thereby reducing the phase difference between voltage and current, allowing maximum electrical energy to be extracted from AC input 104. Examples of PFC converter 104A include, but are not limited to, PFC boost converters, active PFC converters, etc.

[0075] The AC / DC converter 106 on the mains side includes appropriate logic, circuitry, interface, or code for converting the DC power supply into AC power.

[0076] Transformer 108 includes appropriate logic, circuitry, interface, or code for magnetically coupling to the TX pad 120A of an external wireless power transmitter (WPT) 120, enabling the AC side coil 108A and the battery side coil 108B to receive electrical energy.

[0077] The battery-side AC / DC converter 110 includes appropriate logic, circuitry, interface, or code for converting the AC power supply into DC power.

[0078] The battery connector 112 includes appropriate logic, circuitry, interface, or code for providing the DC power to the battery.

[0079] One or more bypass switches 114 include appropriate logic, circuitry, interfaces, or code for electrically connecting the AC-side converter (i.e., AC-side DC / AC converter 106) to the battery-side converter (i.e., battery-side AC / DC converter 110) when the one or more bypass switches are closed. Each of the one or more bypass switches 114 may be a DC switch. For example, Figure 6 The text describes in more detail the structural and functional connections between the various components of the OBC device 102.

[0080] During operation, with bypass switch 114 closed and transformer 108 magnetically coupled to WPT 120, electrical energy is transferred to battery connector 112 via the battery-side converter (i.e., battery-side AC / DC converter 110) and the AC / DC converter (i.e., AC / DC converter 106). When one or more bypass switches 114 are closed and transformer 108 is magnetically coupled to the TX pad 120A of WPT 120, OBC device 102 functions as a wireless charger (WC). In this configuration, transformer 108 functions as the receiver (RX) pad of the WC. AC / DC coil 108A and battery-side coil 108B operate in parallel, feeding their energy to their respective power converters; for example, AC / DC coil 108A feeds energy to AC / DC converter 106, and battery-side coil 108B feeds energy to battery-side AC / DC converter 110. In this configuration, both the AC / DC converter 106 on the mains side and the AC / DC converter 110 on the battery side are used simultaneously, thereby increasing the rated power. The WC is used for wireless charging of the battery, therefore the WC can be used in electric vehicles.

[0081] According to one embodiment, the OBC device 102 further includes: a mains-side resonant slot 116 having a first capacitor and a first inductor; and a battery-side resonant slot 118 having a second capacitor and a second inductor. The values ​​of the first capacitor and the first inductor of the mains-side resonant slot 116 are selected to allow the OBC device 102 to operate via the mains input terminal 104; the values ​​of the second capacitor and the second inductor of the battery-side resonant slot 118 are selected to allow the OBC device 102 to operate via the WPT 120. The mains-side resonant slot 116 and the battery-side resonant slot 118 together serve as a CLLC resonant slot. The CLLC resonant slot refers to a capacitor (C)-inductor (L)-inductor (L)-capacitor (C) resonant slot. The first inductor of the mains-side resonant slot 116 and the second inductor of the battery-side resonant slot 118 serve as the leakage inductance of the CLLC resonant slot. For example, Figure 4 The first capacitor of the mains-side resonant slot 116 and the second capacitor of the battery-side resonant slot 118 are described in more detail.

[0082] According to one embodiment, the values ​​of the first capacitor and the first inductor of the mains-side resonant slot 116 are selected to correspond to the first resonant frequency when the OBC device operates through the mains input terminal 104; the values ​​of the second capacitor and the second inductor of the battery-side resonant slot 118 are selected to correspond to the second resonant frequency when the OBC device operates through the WPT 120. The values ​​of the first capacitor and the first inductor of the mains-side resonant slot 116 are selected to define the first resonant frequency of the CLLC resonant slot (i.e., the combination of the mains-side resonant slot 116 and the battery-side resonant slot 118) when it operates through the mains input terminal 104; the values ​​of the second capacitor and the second inductor of the battery-side resonant slot 118 are selected to define the second resonant frequency of the CLLC resonant slot when it operates through the WPT 120.

[0083] According to one embodiment, transformer 108 is used to operate via AC input 104 at a first resonant frequency typically in the range of 200 kHz to 600 kHz (higher frequencies are also possible), and via WPT 120 at a second resonant frequency typically in the range of 80 kHz to 90 kHz. In one case, transformer 108 is used to operate via AC input 104 typically in the range of 200 kHz to 600 kHz when one or more bypass switches 114 are open. The first resonant frequency, which may be higher than the 200 kHz to 600 kHz range, may also be used. In other words, OBC device 102 is used to operate via AC input 104 at the first resonant frequency when one or more bypass switches 114 are open. In another case, transformer 108 is used to operate via WPT 120 at the second resonant frequency typically in the range of 80 kHz to 90 kHz when one or more bypass switches 114 are closed. In other words, when one or more bypass switches 114 are closed, the OBC device 102 is used to operate via WPT 120 at the second resonant frequency in the range of 80 kHz to 90 kHz.

[0084] According to one embodiment, the mains-side resonant groove 116 includes a first capacitor 116A for generating the first capacitance, and the battery-side resonant groove 118 includes a second capacitor 118A for generating the second capacitance. Similarly, the battery-side resonant groove 118 includes a second capacitor 118A for generating the second capacitance. For example, Figure 4 This is described in more detail in [the text].

[0085] According to one embodiment, the mains-side coil 108A and the battery-side coil 108B are configured to overlap with offset to simultaneously generate the first inductance of the mains-side resonant slot 116 and the second inductance of the battery-side resonant slot 118. The mains-side coil 108A and the battery-side coil 108B of the transformer 108 are configured to overlap with offset (i.e., partially) to simultaneously generate the first inductance of the mains-side resonant slot 116 and the second inductance of the battery-side resonant slot 118. The mains-side coil 108A and the battery-side coil 108B are used for partial overlap (i.e., offset overlap) to induce a larger mutual inductance and a smaller leakage inductance. The partial overlap between the mains-side coil 108A and the battery-side coil 108B can be achieved in various ways. For example, in one configuration, the mains-side coil 108A and the battery-side coil 108B may be offset from their respective center points; or, in a second configuration, the mains-side coil 108A and the battery-side coil 108B may extend laterally to partially overlap; or, in a third configuration, the mains-side coil 108A and the battery-side coil 108B may extend along different axes to partially overlap. For example, Figure 11A , Figure 12A and Figure 13A All such configurations are described in detail in [the document / document].

[0086] According to one embodiment, the bypass switch (i.e., one or more bypass switches 114) is a DC switch. The one or more bypass switches 114 are direct current (DC) switches used to regulate the operation of the OBC device 102 via the mains input terminal 104 or via the WPT 120.

[0087] According to one embodiment, each of the mains-side converter (i.e., mains-side DC / AC converter 106) and the battery-side converter (i.e., battery-side AC / DC converter 110) is a full-bridge converter, a half-bridge converter, or a diode bridge converter. Each of the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110 is an active full-bridge converter or a half-bridge converter. When bidirectional power flow is not required, the battery-side AC / DC converter 110 may be a passive converter, such as a diode bridge converter.

[0088] Therefore, the OBC device 102 serves as both the on-board charging device and the wireless charging device for the battery. When one or more bypass switches 114 are open, the OBC device 102 serves as the on-board charging device for the battery. When one or more bypass switches 114 are closed, the OBC device 102 serves as the wireless charging device for the battery. In this way, the OBC device can be used as both the on-board charging device and the wireless charging device for the battery, thereby exhibiting higher power density at a significantly reduced cost.

[0089] Figure 2 A block diagram illustrating various exemplary components of an electric vehicle provided in one embodiment of the present invention is shown. Figure 2 It is a combination Figure 1 The elements described in [the document / reference]. Figure 2 The figure shows an on-board charging (OBC) device 102. Figure 1 Block diagram 200 of electric vehicle 202 and battery 204.

[0090] Electric vehicle 202 includes appropriate logic, circuitry, interfaces, or code for partial or full charging via battery 204. Because electric vehicle 202 includes OBC device 102, it can be charged via battery 204 and wirelessly. Electric vehicle 202 has a higher rated power and lower cost. Examples of electric vehicle 202 include, but are not limited to, pure electric vehicles, plug-in hybrid electric vehicles, and hybrid electric vehicles.

[0091] Figure 3 A block diagram of various exemplary components of a system for wirelessly charging electric vehicles, provided by an embodiment of the present invention, is shown. Figure 3 It is a combination Figure 1 and Figure 2 The elements described in [the document / reference]. Figure 3 The figure shows electric vehicle 202 ( Figure 2 ) and external wireless power transmitter (WPT) 120 ( Figure 1 The block diagram 300 of system 302 is shown. The external WPT 120 includes the TX pad 120A.

[0092] System 302 is used for electric vehicles (e.g., electric vehicle 202). Figure 2 Wireless charging is performed. In one case, system 302 functions as OBC device 102, which charges the battery 204 of electric vehicle 202. In this case, system 302 operates via an AC power input (e.g., AC power input 104).

[0093] In another scenario, system 302 functions as a wireless charger (WC) to charge the battery 204 of electric vehicle 202. In this case, system 302 operates via an external power source. For this purpose, the external WPT 120 includes a TX pad 120A for transmitting wireless power to the transformer 108 of the OBC device 102 in electric vehicle 202. In this scenario, the OBC device 102 functions as the WC.

[0094] In one implementation, the WPT 120 is used to operate at a resonant frequency in the range of 80 kHz to 90 kHz. In another case, when system 302 is used as the WC, the WPT 120 is used to operate at a resonant frequency in the range of 80 kHz to 90 kHz.

[0095] In this way, system 302 enables the OBC device 102 and the WC to operate at two independent frequencies without adding or removing resonant elements (e.g., inductors or capacitors). Therefore, system 302 exhibits higher power density at a significantly reduced cost.

[0096] Figure 4 A circuit diagram of a system provided by an embodiment of the present invention is shown, in which an on-board charging (OBC) device is shown operating via an AC power input and an external wireless power transmitter (WPT). Figure 4 It is a combination Figure 1 , Figure 2 and Figure 3 The elements described in [the document / reference]. Figure 4 The figure illustrates an OBC device (e.g., OBC device 102). Figure 1 The system 400 operates via AC power input 104 and external WPT 120.

[0097] The external WPT 120 includes a power factor correction (PFC) converter 120B, which corresponds to the PFC converter 104A of the OBC device 102.

[0098] In one scenario, the OBC device 102 operates via the mains input terminal 104 when one or more bypass switches 114 (also denoted as S1) are open. In another scenario, the OBC device 102 operates via an external WPT 120 when one or more bypass switches 114 (i.e., S1) are closed. In still other scenarios, the OBC device 102 can be used as a wireless charger (WC) for charging an electric vehicle 202 ( Figure 2 The battery 204 of the WC is wirelessly charged. In other cases, the transformer 108 of the OBC device 102 can be used as the RX pad of the WC, which receives wireless power from the TX pad 120A of the external WPT 120. In this case, the RX pad of the WC is magnetically coupled to the TX pad 120A of the external WPT 120, and the magnetic coupling is indicated by the dashed circle 402. Thus, in one case, the OBC device 102 operates as the WC when one or more bypass switches 114 (i.e., S1) are closed and the RX pad of the WC is magnetically coupled to the TX pad 120A of the external WPT 120. Due to the magnetic coupling between the TX pad 120A of the external WPT 120 and the RX pad of the WC, an excitation inductance can be induced. In this case, the AC side coil 108A and the battery side coil 108B of the RX pad (i.e., transformer 108) of the WC are used to operate in parallel to feed electrical energy to their respective power converters. That is, the mains-side coil 108A is used to feed electrical energy to the mains-side DC / AC converter 106; the battery-side coil 108B is used to feed electrical energy to the battery-side AC / DC converter 110. In this case, the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110 are used simultaneously, thereby increasing the rated power, for example, making the rated power twice the rated power of the OBC device 102. The mains-side coil 108A and the battery-side coil 108B of the RX pad (i.e., transformer 108) of the WC are electrically isolated. Compared with the conventional method, when the OBC device 102 is operating as the WC, each of the mains-side coil 108A and the battery-side coil 108B is used simultaneously to transmit electrical energy to the battery 204. In this way, each of the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110, as well as each of the mains-side coil 108A and the battery-side coil 108B, can be used simultaneously to improve the rated power and utilization rate. Furthermore, by diverting current and electrical energy to two converters (i.e., mains-side coil 108A and battery-side coil 108B) and two coils (i.e., mains-side coil 108A and battery-side coil 108B), copper utilization is improved and current stress and losses are reduced.

[0099] In this configuration, when the OBC device 102 is used to operate via the mains input terminal 104, the RX pad of the WC serves as a transformer 108 (e.g., an isolation transformer) for the OBC device 102. The OBC device 102 includes a CLLC resonant channel comprised of a mains-side resonant channel 116 and a battery-side resonant channel 118. The mains-side resonant channel 116 includes a first capacitor 116A (also denoted as Cr1) for generating the first capacitance. Furthermore, the mains-side resonant channel 116 includes the first inductor (also denoted as Lr1). Similarly, the battery-side resonant channel 118 includes a second capacitor 118A (also denoted as Cr2) for generating the second capacitance. Furthermore, the battery-side resonant channel 118 includes the second inductor (also denoted as Lr2). The first inductor (i.e., Lr1) and the second inductor (i.e., Lr2) can serve as leakage inductance for the CLLC resonant channel. Therefore, the method described herein does not require additional magnetic components compared to conventional methods that require more inductors and capacitors. Furthermore, the ratio between the leakage inductance and the magnetizing inductance can be adjusted by adjusting the offset overlap between the two coils (i.e., the AC side coil 108A and the battery side coil 108B), wherein the two coils constitute the transformer 108 of the OBC device 102.

[0100] The OBC device 102, operating via AC input 104 and WPT 120, can generate bidirectional power flow. Furthermore, system 400 enables the OBC device 102 and the WC to operate at two independent frequencies without adding or removing resonant elements (i.e., inductors or capacitors). Compared to conventional methods, system 400 offers higher power density and lower cost. Power density is increased by eliminating the conventional OBC transformer and resonant tank inductor, as well as the AC / DC converter of a conventional WC system, and by increasing the rated power when the OBC device 102 is used as the WC. The cost of system 400 is reduced by eliminating the conventional OBC transformer and additional resonant tank inductor, as well as the AC / DC converter of a conventional WC system, and by integrating system 400 into a single printed circuit board (PCB) with a shared housing and cooling system. Furthermore, the use of a shared controller and gate drive circuit also reduces the cost of system 400.

[0101] Figure 5A A schematic diagram of the coil structure of the transformer of an OBC device provided in one embodiment of the present invention is shown. Figure 5A It is a combination Figure 1 and Figure 4 The elements described in [the document / reference]. Figure 5A The figure shows OBC device 102 ( Figure 1The transformer 108 has a coil structure 500A. The transformer 108 includes an AC side coil 108A and a battery side coil 108B.

[0102] Each of the mains-side coil 108A and the battery-side coil 108B is offset from its respective center point to form a partial overlap between them. This partial overlap between the mains-side coil 108A and the battery-side coil 108B introduces a larger mutual inductance and a smaller leakage inductance into the CLLC resonant slot. Conventionally, coils in WC systems are designed with zero or large overlap to eliminate the mutual inductance. Compared to conventional coils, the mains-side coil 108A and the battery-side coil 108B introduce a larger mutual inductance (i.e., magnetizing inductance) and a smaller leakage inductance into the CLLC resonant slot. Therefore, the method described herein does not require additional magnetic components compared to conventional methods that require more inductors and capacitors. Furthermore, the ratio between the leakage inductance and the magnetizing inductance can be adjusted by regulating the partial overlap between the two coils (i.e., the mains-side coil 108A and the battery-side coil 108B), which constitute the transformer 108 of the OBC device 102. Figure 11A , Figure 12A and Figure 13A The different arrangements of the mains-side coil 108A and battery-side coil 108B, as described in detail, enable the integration of leakage inductance and magnetizing inductance in the RX pad of the WC. When the OBC device 102 is used to operate via an external WPT 120, the mains-side coil 108A and battery-side coil 108B of the transformer 108 may also be referred to as the mains-side coil 108A and battery-side coil 108B of the RX pad of the WC.

[0103] Figure 5B A graphical representation of the change in the ratio between leakage inductance and magnetizing inductance as the overlap between the two coils of the transformer in an OBC device increases, provided by an embodiment of the present invention, is shown. Figure 5B It is a combination Figure 1 , Figure 4 and Figure 5A The elements described in [the document / reference]. Figure 5B The figure 500B shows a graphical representation of the change in the ratio between leakage inductance and magnetizing inductance as the overlap between the two coils (i.e., mains-side coil 108A and battery-side coil 108B) of the transformer 108 of the OBC device 102 increases.

[0104] Graphical representation 500B includes an X-axis 502, which shows the overlap (in centimeters) between the AC side coil 108A and the battery side coil 108B of the transformer 108 of the OBC device 102. Graphical representation 500B also includes a Y-axis 504, which shows the ratio (k=Lm / Lr) between the leakage inductance and the magnetizing inductance induced by the overlap between the AC side coil 108A and the battery side coil 108B of the transformer 108 of the OBC device 102. In graphical representation 500B, the first line 506 represents the change in the ratio (k=Lm / Lr) between the leakage inductance and the magnetizing inductance as the overlap between the AC side coil 108A and the battery side coil 108B of the transformer 108 of the OBC device 102 increases. The first line 506 indicates that the ratio between the leakage inductance and the magnetizing inductance decreases as the overlap between the AC side coil 108A and the battery side coil 108B increases.

[0105] Figure 6 A block diagram of various exemplary components of a system for wirelessly charging an electric vehicle, provided by an embodiment of the present invention, is shown. Figure 6 It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5A The elements described in [the document / reference]. Figure 6 The figure illustrates the use of electric vehicles (e.g., electric vehicle 202). Figure 2 Block diagram of system 600 for wireless charging.

[0106] System 600 corresponds to System 302 ( Figure 3 ) and System 400 ( Figure 4 System 600 functions as an OBC device 102 for charging the battery 204 of an electric vehicle 202. Additionally, system 600 functions as a wireless charger (WC) for charging the battery 204 of the electric vehicle 202. Thus, system 600 is configured to operate in two modes (i.e., OBC device 102 and the WC), and is configured to use two AC / DC converters when system 600 operates as the WC. Furthermore, in addition to the TX pad 120A, the external WPT 120 includes a PFC converter 120B, a DC / AC converter 120C, and a resonant tank 120D. Each of the PFC converter 120B, DC / AC converter 120C, and resonant tank 120D of the external WPT 120 corresponds to the PFC converter 104A, the AC / AC converter 106, and the AC / AC resonant tank 116 of the OBC device 102, respectively.

[0107] When one or more bypass switches 114 (i.e., S1) are open and the system 600 is used as the OBC device 102, the mains input 104 is used. The mains input 104 can be a power grid that supplies power to the PFC converter 104A. The PFC converter 104A is used to regulate the power factor of the power supplied by the mains input 104. After regulating the power factor, the power is converted from the DC domain to the AC domain using the mains-side DC / AC converter 106. The mains-side DC / AC converter 106 is also used to drive the power with a higher frequency current. Similarly, the battery-side AC / DC converter 110 is used to convert the power from the AC domain to the DC domain. Each of the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110 is an active full-bridge converter (or rectifier). However, a half-bridge rectifier can also be used as the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110. If bidirectional power flow is not required, the battery-side AC / DC converter 110 can be a diode bridge converter. Furthermore, a mains-side resonant slot 116 is placed between the transformer 108 and the mains-side DC / AC converter 106. To maintain symmetry in the system 600, a battery-side resonant slot 118 is placed between the transformer 108 and the battery-side AC / DC converter 110. The mains-side resonant slot 116 and the battery-side resonant slot 118 are used to define a first resonant frequency of the OBC device 102, typically in the range of 200 kHz to 600 kHz. A first resonant frequency higher than the 200 kHz to 600 kHz range may also be used. To define the first resonant frequency of the OBC device 102, the values ​​of the first capacitor and the first inductor of the mains-side resonant slot 116 and the values ​​of the second capacitor and the second inductor of the battery-side resonant slot 118 can be adjusted accordingly. The first capacitance of the mains-side resonant slot 116 is adjusted by using a first capacitor 116A (i.e., Cr1); the second capacitance of the battery-side resonant slot 118 is adjusted by using a second capacitor 118A (i.e., Cr2). Using the first capacitor 116A and the second capacitor 118A simplifies the structure of system 600. Furthermore, the first inductance (i.e., Lr1) of the mains-side resonant slot 116 and the second inductance (i.e., Lr2) of the battery-side resonant slot 118 are adjusted by adjusting the overlap between the mains-side coil 108A and the battery-side coil 108B of the transformer 108. Electrical energy converted to the DC domain using the battery-side AC / DC converter 110 is supplied to the battery 204 via the battery connector 112. Thus, system 600 is used to operate as an OBC device 102 when one or more bypass switches 114 (i.e., S1) are open.

[0108] When one or more bypass switches 114 (i.e., S1) are closed and system 600 is used as the WC, an external WPT 120 is used. In this case, the transformer 108 of the OBC device 102 is used as the RX pad of the WC. The TX pad 120A of the external WPT 120 is magnetically coupled to the RX pad of the WC. The external WPT 120, including the TX pad 120A, is used to transmit wireless power to the RX pad (i.e., transformer 108) of the WC. The AC side coil 108A and the battery side coil 108B of the RX pad (i.e., transformer 108) of the WC are used to operate in parallel to feed electrical energy to their respective power converters. That is, the AC side coil 108A is used to feed electrical energy to the AC side DC / AC converter 106; the battery side coil 108B is used to feed electrical energy to the battery side AC / DC converter 110. In this case, both the AC / AC converter 106 on the mains side and the AC / DC converter 110 on the battery side are used simultaneously, thereby increasing the rated power (compared to the OBC device 102).

[0109] Therefore, due to the increased rated power of the WC, the system 600 provides a higher rated power; and because the system 600 is integrated into a single PCB with a shared housing and cooling system, the cost is significantly reduced.

[0110] Figure 7 A circuit diagram of a system for operation as an OBC device according to an embodiment of the present invention is shown. Figure 7 It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A and Figure 6 The elements described in [the document / reference]. Figure 7 The figure shows the device used as an OBC device 102 ( Figure 1 The system 700 is working.

[0111] When one or more bypass switches 114 (i.e., S1) are open, system 700 is divided into two electrically isolated sections. Therefore, system 700 is used as an OBC device 102, the first resonant frequency of which is given by Equation 1.

[0112] (1)

[0113] Accordingly, by selecting the capacitor (C) rx ) and inductance (L rxThe value of the first resonant frequency of the OBC device 102 during operation is typically designed to be in the range of 200 kHz to 600 kHz (or higher). In other words, by selecting the values ​​of the first capacitor (Cr1) and the first inductor (Lr1) of the mains-side resonant slot 116 and the values ​​of the second capacitor (Cr2) and the second inductor (Lr2) of the battery-side resonant slot 118, the first resonant frequency of the OBC device 102 can be designed according to the application scenario. The flow of electrical energy in the system 700 when charging a battery (e.g., battery 204 of electric vehicle 202) is further illustrated by arrow 702. Arrow 702 indicates the flow of electrical energy from the mains input terminal 104 to the battery 204 (not shown in the figure). However, if vehicle-to-everything (V2X) operation is required, the flow of electrical energy can be reversed.

[0114] Figure 8A A graphical representation of the voltage waveform of an OBC device provided in an embodiment of the present invention at a sub-resonant frequency is shown. Figure 8A It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 and Figure 7 The elements described in [the document / reference]. Figure 8A The figure shows OBC device 102 ( Figure 1 Graphical representation of the voltage waveform at subresonant frequency 800A. System 700 ( Figure 7 It is used as an OBC device 102.

[0115] The graphical representation 800A includes an X-axis 802, which represents time. The graphical representation 800A also includes a Y-axis 804, which shows the amplitude of the voltage waveform of the OBC device 102. The first waveform 806 represents the input voltage waveform of the OBC device 102 at the sub-resonant frequency. In other words, the first waveform 806 represents the voltage waveform (V) of the AC / DC converter 106 on the mains side of the OBC device 102. con1 The second waveform 808 represents the output voltage waveform of the OBC device 102 at the sub-resonant frequency. In other words, the second waveform 808 represents the voltage waveform (V) of the battery-side AC / DC converter 110. con2 ).

[0116] Figure 8B A graphical representation of the current waveform of an OBC device at a sub-resonant frequency, according to an embodiment of the present invention, is shown. Figure 8B It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 , Figure 7 and Figure 8A The elements described in [the document / reference]. Figure 8B The figure shows OBC device 102 ( Figure 1 Graphical representation of the current waveform at subresonant frequency 800B. System 700 ( Figure 7 It is used as an OBC device 102.

[0117] Graphical representation 800B includes an X-axis 810, which represents time. Graphical representation 800B also includes a Y-axis 812, which shows the amplitude of the current waveform of the OBC device 102. The first waveform 814 represents the current waveform (i) flowing through the first inductor (lr1) of the mains-side resonant slot 116 of the OBC device 102 at a sub-resonant frequency. lr1 The second waveform 816 represents the current waveform (i) flowing through the second inductor (lr2) of the battery-side resonant tank 118 of the OBC device 102 at a sub-resonant frequency. lr2 ).

[0118] Figure 8C A graphical representation of the voltage waveform of an OBC device provided in an embodiment of the present invention at the resonant frequency is shown. Figure 8C It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 , Figure 7 and Figure 8A The elements described in [the document / reference]. Figure 8C The figure shows OBC device 102 ( Figure 1 A graphical representation of the voltage waveform at the resonant frequency (e.g., the first resonant frequency) 800C. System 700 ( Figure 7 This is used to operate as an OBC device 102. The resonant frequency of the OBC device 102 (i.e., the first resonant frequency) is typically in the range of 200 kHz to 600 kHz. The first resonant frequency may also be in a range higher than 200 kHz to 600 kHz.

[0119] The graphical representation 800C includes an X-axis 818, which represents time. The graphical representation 800C also includes a Y-axis 820, which shows the amplitude of the voltage waveform of the OBC device 102. A first waveform 822 represents the voltage waveform of the OBC device 102 at its resonant frequency (i.e., the first resonant frequency). In other words, the first waveform 822 represents the voltage waveform (V0) of the battery-side AC / DC converter 110 of the OBC device 102. con2 ).

[0120] Figure 8D A graphical representation of the current waveform of an OBC device provided in an embodiment of the present invention at the resonant frequency is shown. Figure 8D It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 8B and Figure 8C The elements described in [the document / reference]. Figure 8D The figure shows OBC device 102 ( Figure 1 Graphical representation of the current waveform at the resonant frequency (800D). System 700 ( Figure 7 It is used as an OBC device 102.

[0121] The graphical representation 800D includes an X-axis 824, which represents time. The graphical representation 800D also includes a Y-axis 826, which shows the amplitude of the current waveform of the OBC device 102. The first waveform 828 represents the current waveform (i) flowing through the first inductor (lr1) of the mains-side resonant slot 116 of the OBC device 102 at the resonant frequency. lr1 The second waveform 830 represents the current waveform (i) flowing through the second inductor (lr2) of the battery-side resonant tank 118 of the OBC device 102 at the resonant frequency. lr2 ).

[0122] Figure 9 A circuit diagram of a system for functioning as a wireless charger (WC) according to an embodiment of the present invention is shown. Figure 9 It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A and Figure 6 The elements described in [the document / reference]. Figure 9 The figure shows a system 900 used as a wireless charger.

[0123] When one or more bypass switches 114 (i.e., S1) are closed and transformer 108 is magnetically coupled to the TX pad 120A of the external WPT 120, OBC device 102 is used as the wireless charger (WC), and therefore system 900 is used as the wireless charger (WC). In this configuration, transformer 108 of OBC device 102 functions as the RX pad of the WC. The two isolation coils of the RX pad of the WC (i.e., AC side coil 108A and battery side coil 108B) operate in parallel. System 900 is similar to a series-compensated inductive power transfer system. First capacitor 116A (C r1 ) and the second capacitor 118A (C r2 This forms a resonant circuit with leakage inductance and magnetizing inductance. The second resonant frequency of system 900 is given by Equation 2.

[0124] (2)

[0125] According to standard J2954, the second resonant frequency of the WC can be designed to be approximately 85 kHz. Standard J2954 specifies the frequency for use in electric vehicles (EVs) (e.g., electric vehicle 202...). Figure 2 The operating frequency of the WC is specified. Furthermore, three arrows are used to indicate the direction of electrical energy flow in system 900. However, the direction of electrical energy flow can be reversed based on the application.

[0126] Figure 10A A graphical representation of the voltage waveform of WC at the second resonant frequency provided by an embodiment of the present invention is shown. Figure 10A It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 and Figure 9 The elements described in [the document / reference]. Figure 10A The figure shows a graphical representation of the voltage waveform of WC at the second resonant frequency (1000A). System 900 ( Figure 9 This is used as the WC for operation. The second resonant frequency of the WC can be designed to be approximately 85 kHz.

[0127] The graphical representation 1000A includes an X-axis 1002, which represents time. The graphical representation 1000A also includes a Y-axis 1004, which shows the amplitude of the voltage waveform of the WC. A first waveform 1006 represents the voltage waveform of the WC at the second resonant frequency. In other words, the first waveform 1006 represents the voltage waveform (V) of the battery-side AC / DC converter 110 of the WC. con2 ).

[0128] Figure 10B A graphical representation of the current waveform of WC at the second resonant frequency provided by an embodiment of the present invention is shown. Figure 10B It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5A , Figure 6 , Figure 9 and Figure 10A The elements described in [the document / reference]. Figure 10B The figure shows a graphical representation of the current waveform of WC at the second resonant frequency 1000B. System 900 ( Figure 9 ) is used as the WC work.

[0129] Graphical representation 1000B includes an X-axis 1008, which represents time. Graphical representation 1000B also includes a Y-axis 1010, which shows the amplitude of the current waveform of the WC. The first waveform 1012 represents the current waveform (i) flowing through the second inductor (lr2) of the battery-side resonant tank 118 of the WC at the resonant frequency. lr2 The second waveform, 1014, represents the current waveform flowing through the 120A TX pad of the external WPT 120 (I). tx_coil The second waveform 1014 (I) flowing through the TX pad 120A. tx_coil ) indicates variable current, which means that when system 900 is operating as the WC, an external WPT 120 is used.

[0130] Figure 11A A schematic diagram of the coil structure of the transformer of an OBC device provided in one embodiment of the present invention is shown. Figure 11A It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 and Figure 9 The elements described in [the document / reference]. Figure 11A The figure shows OBC device 102 ( Figure 1The transformer 108 has a coil structure 1100A. The transformer 108 includes an AC side coil 108A and a battery side coil 108B. When the OBC device 102 is used to operate via an external WPT 120, each of the AC side coil 108A and the battery side coil 108B may also be referred to as two electrically isolated coils of the RX pad of the WC.

[0131] Each of the mains-side coil 108A and the battery-side coil 108B is also used to sense the embedded leakage inductance and magnetizing inductance in the OBC device 102 and the WC. The ratio (k) between the magnetizing inductance and the embedded leakage inductance is controlled by adjusting the overlap between each of the mains-side coil 108A and the battery-side coil 108B. The overlap between the mains-side coil 108A and the battery-side coil 108B can be achieved in different ways. For example, in coil structure 1100A, each of the mains-side coil 108A and the battery-side coil 108B is offset from its respective center point to form a partial overlap between the two coils.

[0132] Figure 11B A graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in an embodiment of the present invention is shown. Figure 11B It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 9 and Figure 11A The elements described in [the document / reference]. Figure 11B The figure shows a graphical representation 1100B of the embedded leakage inductance and mutual inductance induced in each of the mains side coil 108A and battery side coil 108B of the transformer 108 of the OBC device 102.

[0133] Graphical representation 1100B includes an X-axis 1102, which shows the overlap (in centimeters, cm) between each of the mains-side coil 108A and the battery-side coil 108B. Graphical representation 1100B also includes a Y-axis 1104, which shows the inductance (in microhenries, µH) induced by the overlap between each of the mains-side coil 108A and the battery-side coil 108B. The first line 1106 and the second line 1108 show the self-inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. The third line 1110 and the fourth line 1112 show the mutual inductance (µH) or magnetizing inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. Lines 1114 and 1116 show the embedded leakage inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. In graphic representation 1100B, each of the mutual inductance and the embedded leakage inductance is obtained when each of the mains-side coil 108A and the battery-side coil 108B is deviated from its respective center point. The self-inductance, the mutual inductance, and the embedded leakage inductance may also be generated as part of the WC.

[0134] Figure 12A A schematic diagram of the coil structure of the transformer of an OBC device provided in another embodiment of the present invention is shown. Figure 12A It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 9 and Figure 11A The elements described in [the document / reference]. Figure 12A The figure shows OBC device 102 ( Figure 1 The transformer 108 has a coil structure 1200A. The transformer 108 includes an AC side coil 108A and a battery side coil 108B.

[0135] In coil structure 1200A, each of the mains-side coil 108A and the battery-side coil 108B extends laterally to form a partial overlap between the two coils. In other words, the edge of each of the mains-side coil 108A and the battery-side coil 108B extends in one direction to form the partial overlap between the two coils. The partial overlap between each of the mains-side coil 108A and the battery-side coil 108B is used to adjust the ratio (k) between the magnetizing inductance and the embedded leakage inductance of the WC (i.e., system 900).

[0136] Figure 12BA graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in another embodiment of the present invention is shown. Figure 12B It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 9 , Figure 11B and Figure 12A The elements described in [the document / reference]. Figure 12B The figure shows a graphical representation 1200B of the embedded leakage inductance and mutual inductance induced in each of the mains side coil 108A and the battery side coil 108B of the transformer 108 of the OBC device 102.

[0137] Graphical representation 1200B includes an X-axis 1202, which shows the overlap (in centimeters, cm) between each of the mains-side coil 108A and the battery-side coil 108B. Graphical representation 1200B also includes a Y-axis 1204, which shows the inductance (in microhenries, µH) induced by the overlap between each of the mains-side coil 108A and the battery-side coil 108B. The first line 1206 and the second line 1208 show the self-inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. The third line 1210 and the fourth line 1212 show the mutual inductance (µH) or magnetizing inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. Lines 1214 and 1216 show the embedded leakage inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. In graphic representation 1200B, each of the mutual inductance and the embedded leakage inductance is obtained when each of the mains-side coil 108A and the battery-side coil 108B extends laterally. Each of the self-inductance, the mutual inductance, and the embedded leakage inductance may also be generated as part of the WC.

[0138] Figure 13A A schematic diagram of the coil structure of the transformer of an OBC device provided in another embodiment of the present invention is shown. Figure 13A It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 9 , Figure 11A and Figure 12A The elements described in [the document / reference]. Figure 13A The figure shows OBC device 102 ( Figure 1The transformer 108 has a coil structure 1300A. The transformer 108 includes an AC side coil 108A and a battery side coil 108B.

[0139] In coil structure 1300A, each of the mains-side coil 108A and the battery-side coil 108B extends along different axes to form a partial overlap between the two coils. In other words, the edges of each of the mains-side coil 108A and the battery-side coil 108B extend in two different directions to form the partial overlap between the two coils. This partial overlap between each of the mains-side coil 108A and the battery-side coil 108B is used to adjust the ratio (k) between the magnetizing inductance and the embedded leakage inductance of the WC (i.e., system 900).

[0140] Figure 13B A graphical representation of the leakage inductance and mutual inductance induced in the two coils of the transformer of an OBC device provided in another embodiment of the present invention is shown. Figure 13B It is a combination Figure 1 , Figure 4 , Figure 5A , Figure 6 , Figure 7 , Figure 9 , Figure 11B , Figure 12B and Figure 13A The elements described in [the document / reference]. Figure 13B The figure shows a graphical representation 1300B of the embedded leakage inductance and mutual inductance induced in each of the mains side coil 108A and the battery side coil 108B of the transformer 108 of the OBC device 102.

[0141] Graphical representation 1300B includes an X-axis 1302, which shows the overlap (in centimeters, cm) between each of the mains-side coil 108A and the battery-side coil 108B. Graphical representation 1300B also includes a Y-axis 1304, which shows the inductance (in microhenries, µH) induced by the overlap between each of the mains-side coil 108A and the battery-side coil 108B. The first line 1306 and the second line 1308 show the self-inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. The third line 1310 and the fourth line 1312 show the mutual inductance (µH) or magnetizing inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. Lines 1314 and 1316 show the embedded leakage inductance (µH) of the mains-side coil 108A and the battery-side coil 108B, respectively. In graphic representation 1300B, each of the mutual inductance and the embedded leakage inductance is obtained when each of the mains-side coil 108A and the battery-side coil 108B extends in two different directions. Each of the coil inductance, the mutual inductance, and the embedded leakage inductance can also be generated as part of the WC.

[0142] Figure 14 A flowchart of a method for charging an electric vehicle according to an embodiment of the present invention is shown. Figure 14 It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 6 and Figure 9 The elements described in [the document / reference]. Figure 14 The figure illustrates the use of electric vehicles (e.g., electric vehicle 202). Figure 2 Method 1400 for charging. Method 1400 includes steps 1402 and 1404. In OBC device 102 ( Figure 1 When used with WPT 120, method 1400 is executed by OBC device 102. Additionally, method 1400 can also be executed by system 900. Figure 9 )implement.

[0143] A method for charging an electric vehicle 202 (i.e., method 1400) includes:

[0144] The transformer 108 is magnetically coupled to the TX pad 120A of the external wireless power transmitter (WPT) 120, so that the AC side coil 108A and the battery side coil 108B receive electrical energy.

[0145] One or more bypass switches 114 (i.e., S1) are closed to electrically connect the AC-side converter (i.e., AC-side DC / AC converter 106) to the battery-side converter (i.e., battery-side AC / DC converter 110), thereby transferring electrical energy to the battery connector 112 through the battery-side converter (i.e., battery-side AC / DC converter 110) and the AC-side converter (i.e., AC-side DC / AC converter 106).

[0146] In step 1402, method 1400 includes: magnetically coupling transformer 108 to the TX pad 120A of an external wireless power transmitter (WPT) 120, such that the AC-side coil 108A and the battery-side coil 108B receive electrical energy. When the OBC device 102 included in the electric vehicle 202 is used as a wireless charger (WC), transformer 108 is magnetically coupled to the TX pad 120A of the external WPT 120 to receive electrical energy. The AC-side coil 108A and the battery-side coil 108B of transformer 108 receive electrical energy to simultaneously feed the energy to the AC-side DC / AC converter 106 and the battery-side AC / DC converter 110.

[0147] In step 1404, method 1400 further includes closing one or more bypass switches 114 (i.e., S1) to electrically connect the mains-side converter (i.e., mains-side DC / AC converter 106) to the battery-side converter (i.e., battery-side AC / DC converter 110), thereby transferring electrical energy to the battery connector 112 through the battery-side converter (i.e., battery-side AC / DC converter 110) and the mains-side converter (i.e., mains-side DC / AC converter 106). When one or more bypass switches 114 (i.e., S1) are closed and transformer 108 is magnetically coupled to the TX pad 120A of WPT 120, the mains-side DC / AC converter 106 and battery-side AC / DC converter 110 are electrically connected and together charge the battery 204 of the electric vehicle 202 through the battery connector 112.

[0148] According to one embodiment, the WPT 120 is used to operate at a resonant frequency in the range of 80 kHz to 90 kHz. When the OBC device 102 is used as the WC, the WPT 120 is used to operate at the resonant frequency in the range of 80 kHz to 90 kHz.

[0149] Steps 1402 to 1404 are merely illustrative, and other alternatives may be provided, in which one or more steps are added, one or more steps are deleted, or one or more steps are provided in a different order, without departing from the scope of the claims herein.

[0150] Figure 15 A flowchart of a method for charging an electric vehicle, according to another embodiment of the present invention, is shown. Figure 15 It is a combination Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 6 and Figure 7 The elements described in [the document / reference]. Figure 15 The figure illustrates the use of electric vehicles (e.g., electric vehicle 202). Figure 2 Method 1500 for charging. Method 1500 includes steps 1502 and 1504. In OBC device 102 ( Figure 1 When operating via AC power input terminal 104, method 1500 is executed by OBC device 102. Furthermore, method 1500 can also be executed by system 700 (…). Figure 7 )implement.

[0151] A method for charging an electric vehicle 202 (i.e., method 1500) includes:

[0152] Connect the AC power input terminal 104 to an external AC power source;

[0153] Disconnect one or more bypass switches 114 (i.e., S1) to disconnect the electrical connection between the mains-side converter (i.e., mains-side DC / AC converter 106) and the battery-side converter (i.e., battery-side AC / DC converter 110), thereby transferring electrical energy to the mains-side coil 108A of the transformer 108.

[0154] In step 1502, method 1500 includes connecting the AC input terminal 104 to an external AC power source. The OBC device 102 included in the electric vehicle 202 is used to operate via the AC input terminal 104. For this purpose, the AC input terminal 104 is connected to the external AC power source.

[0155] In step 1504, method 1500 further includes: disconnecting one or more bypass switches 114 (i.e., S1) to disconnect the electrical connection between the mains-side converter (i.e., the mains-side DC / AC converter 106) and the battery-side converter (i.e., the battery-side AC / DC converter 110), thereby transferring electrical energy to the mains-side coil 108A of the transformer 108. The electrical connection between the mains-side DC / AC converter 106 and the battery-side AC / DC converter 110 is disconnected when one or more bypass switches 114 are open and the OBC device 102 is used to operate via the mains input terminal 104. In this configuration, electrical energy is transferred from the mains input terminal 104 to the mains-side coil 108A of the transformer 108, and further to the battery 204 of the electric vehicle 202 via the battery connector 112.

[0156] According to one embodiment, the external mains power supply is used to operate at a resonant frequency typically in the range of 200 kHz to 600 kHz. A resonant frequency higher than the 200 kHz to 600 kHz range may also be used. The mains input terminal 104 is connected to the external mains power supply, which is used to operate at the resonant frequency typically in the range of 200 kHz to 600 kHz.

[0157] Steps 1502 to 1504 are merely illustrative, and other alternatives may be provided, in which one or more steps are added, one or more steps are deleted, or one or more steps are provided in a different order, without departing from the scope of the claims herein.

[0158] Modifications to the embodiments of the invention described above may be made without departing from the scope of the invention as defined by the appended claims. The terms “comprising,” “combining,” “having,” “is,” and the like used to describe and claim the invention are intended to be interpreted in a non-exclusive manner, allowing for the presence of items, components, or elements not explicitly described. Singular references should also be interpreted in relation to the plural. The word “exemplary” as used herein means “as an example, instance, or illustration.” Any embodiment described as “exemplary” is not necessarily to be construed as more preferred or advantageous than other embodiments, and / or excludes combinations of features from other embodiments. The word “optionally” as used herein means “provided in some embodiments but not in others.” It should be understood that some features of the invention described in the context of a single embodiment for clarity may also be provided in combination in a single embodiment. Conversely, various features of the invention described in the context of a single embodiment for brevity may also be provided individually, in any suitable combination, or suited to any other described embodiment of the invention.

Claims

1. An on-board charging device (102) for electric vehicles, characterized in that, include: The mains input terminal (104) includes a power factor correction converter (104A). Mains-side DC / AC converter (106); The transformer (108) has an AC side coil (108A) and a battery side coil (108B). Battery-side AC / DC converter (110); Battery connector (112); One or more bypass switches (114) are used to electrically connect the AC / DC converter (106) on the mains side (106) to the AC / DC converter (110) on the battery side (110) when closed. The mains-side resonant slot (116) has a first capacitor and a first inductor; The battery-side resonant slot (118) has a second capacitor and a second inductor; The mains-side coil (108A) and the battery-side coil (108B) are configured to overlap in offset order to simultaneously generate the first inductance of the mains-side resonant slot (116) and the second inductance of the battery-side resonant slot (118). The transformer (108) is used for magnetic coupling to the TX pad (120A) of the external wireless power transmitter (120), so that the mains side coil (108A) and the battery side coil (108B) receive electrical energy. When the bypass switch (114) is closed and the transformer (108) is magnetically coupled to the external wireless power transmitter (120), electrical energy is transmitted to the battery connector (112) through the battery-side AC / DC converter (110) and the mains-side DC / AC converter (106).

2. The on-board charging device (102) according to claim 1, characterized in that, Also includes: Select the values ​​of the first capacitor and the first inductor of the mains-side resonant slot (116) to enable the vehicle-mounted charging device (102) to operate through the mains input terminal (104); select the values ​​of the second capacitor and the second inductor of the battery-side resonant slot (118) to enable the vehicle-mounted charging device (102) to operate through the external wireless power transmitter (120).

3. The on-board charging device (102) according to claim 2, characterized in that, The values ​​of the first capacitor and the first inductor of the mains-side resonant slot (116) are selected to correspond to the first resonant frequency when the vehicle charging device operates through the mains input terminal (104); the values ​​of the second capacitor and the second inductor of the battery-side resonant slot (118) are selected to correspond to the second resonant frequency when the vehicle charging device operates through the external wireless power transmitter (120).

4. The on-board charging device (102) according to claim 3, characterized in that, The transformer (108) is used to operate via the mains input terminal (104) at the first resonant frequency in the range of 200 kHz to 600 kHz, and via the external wireless power transmitter (120) at the second resonant frequency in the range of 80 kHz to 90 kHz.

5. The on-board charging device (102) according to any one of claims 2 to 4, characterized in that, The mains-side resonant groove (116) includes a first capacitor (116A) for generating the first capacitance, and the battery-side resonant groove (118) includes a second capacitor (118A) for generating the second capacitance.

6. The on-board charging device (102) according to claim 1, characterized in that, The bypass switch (114) is a DC switch.

7. The on-board charging device (102) according to claim 1, characterized in that, Each of the mains-side DC / AC converter (106) and the battery-side AC / DC converter (110) is a full-bridge converter, a half-bridge converter, or a diode-bridge converter.

8. An electric vehicle (202), characterized in that, It includes at least one battery (204) and an on-board charging device (102) according to any one of claims 1 to 7.

9. A system (302) for wirelessly charging an electric vehicle (202), characterized in that, include: The electric vehicle (202) according to claim 8; An external wireless power transmitter (120) includes a TX pad (120A) for transmitting wireless power to the transformer (108) of the on-board charging device (102) in the electric vehicle (202).

10. The system (302) according to claim 9, characterized in that, The external wireless power transmitter (120) is used to operate at a resonant frequency in the range of 80 kHz to 90 kHz.

11. A method (1400) for charging the electric vehicle (202) of claim 8, characterized in that, include: The transformer (108) is magnetically coupled to the TX pad (120A) of the external wireless power transmitter (120), so that the mains side coil (108A) and the battery side coil (108B) receive electrical energy; Close one or more bypass switches (114) to electrically connect the AC / AC converter (106) on the mains side to the AC / AC converter (110) on the battery side, thereby transmitting electrical energy to the battery connector (112) through the AC / AC converter (110) on the battery side and the AC / AC converter (106).

12. The method (1400) according to claim 11, characterized in that, The external wireless power transmitter (120) is used to operate at a resonant frequency in the range of 80 kHz to 90 kHz.

13. A method (1500) for charging the electric vehicle (202) of claim 8, characterized in that, include: Connect the mains input terminal (104) to an external mains power source; Disconnect one or more bypass switches (114) to disconnect the electrical connection between the mains-side DC / AC converter (106) and the battery-side AC / DC converter (110), thereby transferring electrical energy to the mains-side coil (108A) of the transformer (108).

14. The method (1500) according to claim 13, characterized in that, The external AC power supply is used to operate at resonant frequencies in the range of 200 kHz to 600 kHz.

Images