Vehicle-mounted wired and wireless integrated integrated charging system and method

Abstract

The application provides a vehicle-mounted end wired and wireless integrated integrated charging system and method, which comprises a double-port receiving coil structure reversely wound on both sides of a magnetic core and a multi-winding integrated transformer; two receiving coils are wound on the side columns of the magnetic core on the left and right sides of the transformer in opposite directions; the primary winding of the wired charging is wound on the middle column of the magnetic core in the center of the transformer, and the secondary winding and the auxiliary winding are wound on the side columns of the magnetic core on the left and right sides of the transformer; the switching between the two working modes is realized by guiding the magnetic flux generated in the working process of the system. By integrating the wired charging and the wireless charging of the electric vehicle, the vehicle-mounted end charging system supporting the two charging modes is obtained, the power density can be better increased, the overall cost of the charging system can be reduced, and the economy of the integrated charging system is improved.

Description

Technical Field

[0001] This invention relates to the field of wireless power transmission and electric vehicle charging technology, specifically to an integrated wired and wireless charging system and method for vehicle-mounted charging. Background Technology

[0002] Currently, wired charging is the primary method used in the electric vehicle (EV) charging market. However, inductive wireless charging, with its significantly improved safety and convenience, is also attracting technological attention. In the foreseeable future, both wired and wireless charging methods will be used simultaneously in EV charging, creating a huge market for EV charging systems that support both modes. Figure 1 As shown, a typical wired charging system for electric vehicles includes mains rectification, a DC-DC converter, and a battery charging circuit. The DC-DC converter usually employs an isolated DC-DC converter with a transformer to provide a safer and more reliable power connection; however, the transformer's large space occupation indirectly increases the system cost. The structure of a wireless charging system for electric vehicles is as follows: Figure 2 As shown, it includes the mains rectification stage, DC-AC stage, and transmitting coil stage at the non-vehicle end, and the receiving coil stage, AC-DC stage, and battery charging circuit at the vehicle end. Both the transmitting and receiving coil stages in the electric vehicle wireless charging system include coils and resonant compensation networks connected to them.

[0003] Electric vehicle charging systems that support both charging modes typically reuse some components to reduce the overall space required and hardware costs of the charging system, such as... Figure 3 As shown, by sharing the secondary AC-DC converter and battery charging stage, the additional space occupied by wired and wireless integration can be greatly reduced, and costs can be lowered. However, directly connecting the receiving coil and AC output of the wireless charging system to the AC-DC converter stage on the secondary side of the electric vehicle will cause mutual interference and electromagnetic interference when the wired and wireless charging systems are working separately. For example, when wired charging is working and wireless charging is not working, the current transmitted to the secondary side of the wired charging system through the transformer will also flow into the receiving coil of the wireless charging system, causing the receiving coil to generate an electromagnetic field and emit energy outward, resulting in additional power loss and electromagnetic interference. When wireless charging is working and wired charging is not working, the current transmitted from the transmitting coil to the receiving coil of the wireless charging system will also flow into the secondary side of the wired charging transformer and couple to the primary side of the transformer, causing additional losses or even damaging the primary circuit of the wired charging system's inverter circuit.

[0004] In existing in-vehicle wired-wireless integrated solutions, switching between two charging modes is generally achieved through a switching device to avoid interference to the other circuitry caused by one charging mode operating. However, the introduction of a switch increases system cost and size, reduces system reliability and stability, and increases system control complexity. Furthermore, using a switching device for charging mode switching cannot completely eliminate mutual interference between the two charging modes: due to the mutual coupling between magnetic components in the wired-wireless integrated system—that is, between the receiving coil and the transformer windings, and between transformer windings—the alternating current on one magnetic component can induce a current on the coupled magnetic component during operation in one charging mode, resulting in additional electromagnetic interference and power loss. Existing in-vehicle wired-wireless integrated solutions primarily optimize system topology and power density, with insufficient consideration given to EMI issues and the additional losses caused by mutual interference between the two charging modes, thus exhibiting some deficiencies in reliability, safety, and effectiveness.

[0005] As mentioned above, existing integrated wired and wireless charging solutions for electric vehicles generally use switching devices that incur additional costs and losses to switch charging modes, and lack solutions to address the magnetic field coupling effects between the two charging processes. In summary, a reliable and safe integrated wired and wireless charging system for electric vehicles needs to meet the following requirements: 1. Utilize as many circuits as possible for both charging modes to reduce overall system space and cost. 2. Decouple the two charging processes, preventing additional losses and electromagnetic radiation from the integrated wired and wireless design. 3. Reduce the use of module switching switches, minimizing additional system control and avoiding extra switching components while ensuring decoupling of the charging processes, thereby improving system reliability and reducing complexity. 4. Wide applicability, supporting normal operation of both charging modes for different power levels and vehicle models.

[0006] Patent document CN114633643A discloses an integrated wired and wireless charging control system, which includes: a wired charging control module, a wireless charging control module, a heat dissipation module, and a housing. This invention adopts a modular design approach, arranging the wired charging control module, the wireless charging control module, and the heat dissipation module in a specific manner within the same housing.

[0007] Existing in-vehicle wired and wireless integrated charging systems only focus on some of the aforementioned functions, making it difficult to meet all requirements simultaneously. Furthermore, there is a lack of fundamental countermeasures to address the magnetic field radiation caused by electromagnetic induction between magnetic components during the two charging processes. This is a significant technical challenge hindering the widespread adoption of in-vehicle wired and wireless integrated charging equipment and the large-scale application of wireless charging for electric vehicles. Summary of the Invention

[0008] To address the shortcomings of existing technologies, the purpose of this invention is to provide an integrated wired and wireless charging system and method for vehicle-mounted applications.

[0009] The vehicle-mounted wired and wireless integrated charging system provided by the present invention includes: a receiving coil structure with dual ports reverse-wound on both sides of a magnetic core and a multi-winding integrated transformer.

[0010] Two receiving coils are wound in opposite directions on the magnetic core side posts on the left and right sides of the transformer; the primary side of the wired charging is wound on the central magnetic core post in the center of the transformer, while the secondary side and auxiliary winding are wound on the magnetic core side posts on the left and right sides of the transformer.

[0011] Switching between the two operating modes is achieved by guiding the magnetic flux generated during system operation.

[0012] Preferably, during the wireless charging process, energy is transferred from the transmitting coil to the receiving coil, and the battery is charged through a shared wired and wireless AC-DC conversion and battery charging process.

[0013] Preferably, the two sets of windings of the receiving coil have the same spatial position and number of turns, are aligned in the vertical direction and are connected to the left and right windings of the transformer core respectively, and the two windings are wound in opposite directions, that is, one is wound clockwise and the other is wound counterclockwise.

[0014] Preferably, in wired charging mode, the primary winding of the wired charging transformer is energized by high-frequency alternating current, which generates magnetic flux of the same magnitude and direction in the magnetic core side column where the two windings of the receiving coil are wound. This generates induced currents in opposite directions on the two windings of the receiving coil. The magnetic fields generated by these two currents will completely cancel each other out, so no current flows through the wireless charging receiving coil during wired charging.

[0015] Preferably, in the wireless charging working mode, the transmitting coil transfers energy to the receiving coil, generating currents of the same magnitude and direction on the two windings of the receiving coil. These two currents generate magnetic fluxes of the same magnitude but opposite directions on the left and right magnetic core side posts wound by the two windings. According to Kirchhoff's magnetic circuit law, the magnetic flux flowing into and out of the middle of the magnetic core is equal. Therefore, no magnetic flux will flow into the middle post of the magnetic core, and thus no induced current will be generated on the primary winding of the wired charging transformer.

[0016] The vehicle-mounted wired and wireless integrated charging method provided by the present invention adopts a receiving coil structure with dual ports reverse-wound on both sides of the magnetic core and a multi-winding integrated transformer.

[0017] Two receiving coils are wound in opposite directions on the magnetic core side posts on the left and right sides of the transformer. The primary side of the wired charging is wound on the central magnetic core post in the center of the transformer. The secondary side of the wired charging and the auxiliary winding are wound on the magnetic core side posts on the left and right sides of the transformer.

[0018] Switching between the two operating modes is achieved by guiding the magnetic flux generated during system operation.

[0019] Preferably, during the wireless charging process, energy is transferred from the transmitting coil to the receiving coil, and the battery is charged through a shared wired and wireless AC-DC conversion and battery charging process.

[0020] Preferably, the two sets of windings of the receiving coil have the same spatial position and number of turns, are aligned in the vertical direction and are connected to the left and right windings of the transformer core respectively, and the two windings are wound in opposite directions, that is, one is wound clockwise and the other is wound counterclockwise.

[0021] Preferably, in wired charging mode, the primary winding of the wired charging transformer is energized by high-frequency alternating current, which generates magnetic flux of the same magnitude and direction in the magnetic core side column where the two windings of the receiving coil are wound. This generates induced currents in opposite directions on the two windings of the receiving coil. The magnetic fields generated by these two currents will completely cancel each other out, so no current flows through the wireless charging receiving coil during wired charging.

[0022] Preferably, in the wireless charging working mode, the transmitting coil transfers energy to the receiving coil, generating currents of the same magnitude and direction on the two windings of the receiving coil. These two currents generate magnetic fluxes of the same magnitude but opposite directions on the left and right magnetic core side posts wound by the two windings. According to Kirchhoff's magnetic circuit law, the magnetic flux flowing into and out of the middle of the magnetic core is equal. Therefore, no magnetic flux will flow into the middle post of the magnetic core, and thus no induced current will be generated on the primary winding of the wired charging transformer.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] (1) By integrating wired and wireless charging for electric vehicles, an on-board charging system that supports both charging methods is obtained, which can better increase power density and reduce the overall cost of the charging system, thus improving the economy of the integrated charging system.

[0025] (2) By using a special transformer and receiving coil integrated decoupling structure, mutual interference between the two working modes is reduced, the reliability and stability of the system are improved, and EMI generation is reduced at the source, thus improving the safety and reliability of the wired and wireless integrated charging system.

[0026] (3) The two working modes can be freely switched without the use of a switch, which reduces the control complexity of the system, reduces equipment wear and tear, and increases the overall working life of the on-board charging system.

[0027] (4) This solution is applicable to all scenarios where wired and wireless charging are integrated. It is not only applicable to electric vehicle charging. The EMI problem and the problem of mutual interference between the two charging modes are highly universal. Attached Figure Description

[0028] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0029] Figure 1 A schematic diagram of the existing wired charging solution for electric vehicles;

[0030] Figure 2 A schematic diagram of an existing wireless charging solution for electric vehicles;

[0031] Figure 3 A schematic diagram of an integrated wired and wireless charging structure for electric vehicles.

[0032] Figure 4 This is a schematic diagram of the wired and wireless integrated charging structure for electric vehicles according to the present invention.

[0033] Figure 5 This is the flux linkage pattern in wired charging mode;

[0034] Figure 6 This is the magnetic flux direction diagram in wireless charging mode. Detailed Implementation

[0035] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0036] Example

[0037] This invention provides an integrated wired and wireless charging system for vehicles, the specific structure of which is as follows: Figure 4As shown, the structure includes a dual-port receiving coil structure wound in opposite directions on both sides of the magnetic core (which can be implemented using one or two receiving coils) and a multi-winding integrated transformer. The two receiving coils are wound in opposite directions on the left and right sides of the transformer's magnetic core (core side posts), while the primary side for wire charging is wound on the core at the center of the transformer (core center post). This allows for stable switching between two operating modes without interference by guiding the magnetic flux generated during system operation. The specific composition and implementation methods of this structure are as follows:

[0038] The receiving coil is an essential component for inductive wireless power transfer and will be installed on the electric vehicle. During wireless charging, energy is transferred from the transmitting coil to the receiving coil, and then the battery is charged through a shared wired / wireless AC-DC conversion and battery charging process. This solution employs a dual-port receiving coil structure with reverse windings on both sides of the magnetic core: the two sets of windings of the receiving coil have almost identical spatial positions and the same number of turns N. The coils are aligned vertically and connected to the left and right windings of the transformer core, respectively. The two windings are wound in opposite directions, one clockwise and the other counterclockwise. The transformer is a crucial multiplexing component in the integrated on-board charging system of the electric vehicle, and it is also a major cause of interference between the two charging modes. Unlike the winding method in traditional transformer structures, the transformer and receiving coil integrated decoupling structure proposed in this solution has the two receiving coil windings wound in opposite directions on the left and right sides of the E-shaped magnetic core. The primary winding of the transformer for wired charging is wound on the central column of the E-shaped magnetic core, while the secondary winding and auxiliary winding are wound on the left and right sides of the E-shaped magnetic core. This structure achieves the following effects:

[0039] (1) In wired charging mode, the primary winding of the wired charging transformer is energized by high-frequency alternating current, which generates magnetic flux Φ of the same magnitude and direction in the magnetic core pillars around which the two windings of the receiving coil are wound. L and Φ R (like Figure 5 As shown, because the two windings are wound in opposite directions, induced currents I in opposite directions will be generated on the two windings of the receiving coil. R and I L The magnetic fields generated by these two currents will almost completely cancel each other out, achieving the effect that no current flows through the wireless charging receiving coil when wired charging is used. This solves the problem of mutual interference caused by induced current in the wireless charging receiving coil when the wired charging circuit shares the secondary power circuit.

[0040] (2) In wireless charging mode, the transmitting coil transfers energy to the receiving coil, generating currents of the same magnitude and direction in the two windings of the receiving coil. These two currents generate magnetic flux linkages Φ of the same magnitude but opposite direction on the left and right magnetic core side posts wound by the two windings. L and ΦR (like Figure 6 As shown, due to Kirchhoff's magnetic circuit law, the magnetic flux flowing into and out of the middle of the magnetic core is equal. Therefore, no magnetic flux will flow into the middle column, and thus no induced current will be generated on the primary winding of the wired charging transformer. This solves the problem of mutual interference caused by the wireless charging receiving coil generating induced current on the primary side of the wired charging transformer when sharing the secondary power circuit.

[0041] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0042] Those skilled in the art will understand that, in addition to implementing the system, apparatus, and their modules provided by this invention in purely computer-readable program code, the same program can be implemented in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers by logically programming the method steps. Therefore, the system, apparatus, and their modules provided by this invention can be considered a hardware component, and the modules included therein for implementing various programs can also be considered structures within the hardware component; alternatively, modules for implementing various functions can be considered both software programs implementing the method and structures within the hardware component.

[0043] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A vehicle-mounted wired and wireless integrated charging system, characterized in that, include: A receiving coil structure with two ports reverse-winding on both sides of a magnetic core and a multi-winding integrated transformer; Two receiving coils are wound in opposite directions on the magnetic core side posts on the left and right sides of the transformer; the primary side of the wired charging is wound on the central magnetic core post in the center of the transformer, while the secondary side and auxiliary winding are wound on the magnetic core side posts on the left and right sides of the transformer. Switching between the two operating modes is achieved by guiding the magnetic flux generated during system operation; In wireless charging mode, the transmitting coil transfers energy to the receiving coil, generating currents of the same magnitude and direction in the two windings of the receiving coil. These two currents generate magnetic fluxes of the same magnitude but opposite direction on the left and right magnetic core side posts wound by the two windings. According to Kirchhoff's magnetic circuit law, the magnetic flux flowing into and out of the middle of the magnetic core is equal. Therefore, no magnetic flux will flow into the middle post of the magnetic core, and thus no induced current will be generated in the primary winding of the wired charging transformer. The two sets of windings of the receiving coil have the same spatial position and number of turns. The coils are aligned in the vertical direction and connected to the left and right windings of the transformer core respectively. The two windings are wound in opposite directions, that is, one is wound clockwise and the other is wound counterclockwise. In wired charging mode, the primary winding of the wired charging transformer is energized with high-frequency alternating current, which in turn generates magnetic flux of the same magnitude and direction in the magnetic core column where the two windings of the receiving coil are wound. This generates induced currents in opposite directions on the two windings of the receiving coil. The magnetic fields generated by these two currents completely cancel each other out, so no current flows through the wireless charging receiving coil during wired charging.

2. The vehicle-mounted wired and wireless integrated charging system according to claim 1, characterized in that, During wireless charging, energy is transferred from the transmitting coil to the receiving coil, and then the battery is charged through a shared AC-DC conversion and battery charging circuit.

3. A vehicle-mounted integrated wired and wireless charging method, characterized in that, It adopts a receiving coil structure with two ports reverse-wound on both sides of the magnetic core and a multi-winding integrated transformer; Two receiving coils are wound in opposite directions on the magnetic core side posts on the left and right sides of the transformer. The primary side of the wired charging is wound on the central magnetic core post in the center of the transformer. The secondary side of the wired charging and the auxiliary winding are wound on the magnetic core side posts on the left and right sides of the transformer. Switching between the two operating modes is achieved by guiding the magnetic flux generated during system operation; In wireless charging mode, the transmitting coil transfers energy to the receiving coil, generating currents of the same magnitude and direction in the two windings of the receiving coil. These two currents generate magnetic fluxes of the same magnitude but opposite direction on the left and right magnetic core side posts wound by the two windings. Based on Kirchhoff's magnetic circuit law, the magnetic fluxes flowing into and out of the middle of the magnetic core are equal, so no magnetic fluxes will flow into the middle post of the magnetic core, and thus no induced current will be generated in the primary winding of the wired charging transformer. The two sets of windings of the receiving coil have the same spatial position and number of turns. The coils are aligned in the vertical direction and connected to the left and right windings of the transformer core respectively. The two windings are wound in opposite directions, that is, one is wound clockwise and the other is wound counterclockwise. In wired charging mode, the primary winding of the wired charging transformer is energized with high-frequency alternating current, which in turn generates magnetic flux of the same magnitude and direction in the magnetic core column where the two windings of the receiving coil are wound. This generates induced currents in opposite directions on the two windings of the receiving coil. The magnetic fields generated by these two currents completely cancel each other out, so no current flows through the wireless charging receiving coil during wired charging.

4. The integrated wired and wireless charging method for vehicle-mounted terminals according to claim 3, characterized in that, During wireless charging, energy is transferred from the transmitting coil to the receiving coil, and then the battery is charged through a shared AC-DC conversion and battery charging circuit.

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