Positioning sensor and inductive charging device

Abstract

The invention relates to a positioning sensor (200, 300, 400) for producing or sensing a magnetic measurement field for positioning an inductive charging device or a vehicle having an inductive charging device relative to another inductive charging device, wherein the positioning sensor comprises at least one ribbon cable (100; 301; 411, 421) comprising N electrically isolated individual lines (100-104; 306), wherein N is an integer, where N>1, and wherein the ribbon cable has two end regions (110, 120) at which each of the N individual lines end, said individual lines being electrically interconnected such that a continuous electrical connection is produced in order to form a coil with N turns.

Description

[0001] Positioning sensor and inductive charging device

[0002] The invention relates to a positioning sensor that can be used to position a component (e.g., an inductive secondary unit) relative to a reference area (e.g., a primary unit). The invention further relates to an inductive charging device.

[0003] Vehicles, particularly road vehicles such as passenger cars, trucks, or buses, with electric drive have an electrical energy storage device in which electrical energy can be stored to operate the vehicle's electric motor. The vehicle's energy storage device can be charged with electrical energy from a power grid. For this purpose, the energy storage device is coupled to the power grid to transfer the electrical energy from the power grid to the vehicle's energy storage device. The coupling can be wired (via a charging cable or a charging robot) and / or wireless (using an inductive coupling between a charging station and the vehicle).

[0004] Sensor windings printed on a flexible foil and wound around the ferrite core of the energy transfer coil are already known from DE 10 2018 210 726 A1. However, this foil is connected at its ends to a rigid circuit board, which is then later connected to the electronics unit.

[0005] Flexible foils, to which the respective copper lines are applied, are known from EP 3 298615 B1. In this disclosure, three spatial axes are covered by a foil, wherein the lines are connected to each other in all axes and the entire unit has two connections. The foil is wound around a ferrite core and then connected to a rigid circuit board or connecting element and contacted to the electronics unit. A charging system for charging the energy storage device of a vehicle can comprise a primary unit, which is arranged, for example, on a floor on which the vehicle is standing. The primary unit can be configured to provide electrical energy, in particular electrical energy from a supply network. A secondary unit of the vehicle can be placed above the primary unit of the vehicle. Furthermore, a transfer of electrical energy from the primary unit to the secondary unit can be effected, for examplevia an electrically conductive connection and / or a magnetic charging field. The electrical energy transferred to the secondary unit can then be used to charge the vehicle's energy storage system.

[0006] By providing a primary unit, located, for example, on the floor of a garage, and a secondary unit located on the underbody of a vehicle, an automated charging process for charging the vehicle's energy storage system can be enabled. However, due to the position of the primary unit, it is difficult for a vehicle user to position the vehicle, and especially the secondary unit, precisely over the primary unit to enable charging.

[0007] The object of the present invention is to enable a precise positioning of a component, e.g. a secondary unit, relative to a reference area (e.g. a primary unit) in an efficient manner.

[0008] The problem is solved in each case by the independent claims. Advantageous embodiments are described, among other things, in the dependent claims. It should be noted that additional features of a patent claim dependent on an independent patent claim can form a separate invention, independent of the combination of all features of the independent patent claim, without the features of the independent patent claim or only in combination with a subset of the features of the independent patent claim, which invention can be made the subject of an independent claim, a divisional application, or a subsequent application. This applies equally to technical teachings described in the description, which can form an invention independent of the features of the independent patent claims.

[0009] According to one aspect, a positioning sensor is described for generating or detecting a magnetic measuring field for positioning an inductive charging device or a vehicle with an inductive charging device relative to another inductive charging device, wherein: the positioning sensor comprises at least one ribbon cable comprising N electrically insulated individual lines, where N is an integer with N>1; the ribbon cable has two end regions at which the N individual lines each end;each end region has two partial end regions, wherein in each case a single outer line of the N individual lines ends in a first partial end region, which runs at the edge of the respective end region, and in each case the remaining N-1 individual lines of the N individual lines end in a second partial end region, wherein the first outer line of a first end region runs at a first edge region of the ribbon cable, which is opposite a second edge region of the ribbon cable, at which the second outer line of a second end region runs; the free end of the first outer line and the free end of the second outer line are designed for separate electrical connection to an electronic device;and the second partial end regions of the two end regions are connected to one another in such a way that the ends of the remaining N-1 individual lines of the first end region ending there are individually electrically connected to the ends of the remaining N-1 individual lines of the second end region ending there, thereby resulting in a continuous electrical connection from the free end of the first outer line to the free end of the second outer line;

[0010] The magnetic measuring field for positioning a (movable) component relative to a (stationary) reference area can have a measuring field frequency in the range of 125 kHz. The component to be positioned can be, for example, an (inductive and / or conductive) secondary unit or a vehicle with a secondary unit. The reference area can be, for example, the (inductive and / or conductive) primary unit. The positioning sensor can thus be designed to enable positioning as part of an automatic, inductive and / or conductive charging process. The positioning sensor can be part of the component or part of the reference area.

[0011] The positioning sensor comprises at least one ribbon cable comprising N electrically insulated individual wires, where N is an integer with N>1. The N individual wires of the ribbon cable can be arranged parallel to one another, in particular parallel to one another along a longitudinal extension of the ribbon cable or along the orientation of the positioning sensor. Furthermore, the N individual wires of the ribbon cable can be connected to one another via an electrically insulating material, in particular via a plastic layer. The number N of individual wires or wires is typically N=5, 10, 20, or more.

[0012] In one embodiment, the first partial end region of one or both end regions protrudes beyond the second partial end region of the respective end region, in particular over a length in the range of 1 to 10 cm. The first end regions can thus be bent over in order to electrically connect them to another component, e.g., an electronic device.

[0013] In an alternative embodiment, the first partial end region of one or both end regions preferably ends in a line with the second partial end region of the respective end region. Alternatively, the second partial end region of one or both end regions extends beyond the first partial end region of the respective end region.

[0014] The first partial end region is separated from the respective second partial end region along a separation region, in particular along a separation region with a length in the range of 1 to 10 cm, from the respective end. In this way, the first end regions can also be bent over in order to electrically connect them to another component, e.g., an electronic device. Preferably, the second partial end regions of the ribbon cable are glued, welded, fused, or soldered to one another, or connected to one another via an electrically insulating material, in particular via a plastic layer.

[0015] The ends of the N-1 individual lines of the two second partial end regions are preferably individually soldered or welded together to create an electrical connection.

[0016] The positioning sensor may comprise an electronic device, wherein the free ends of the two outer lines are separately electrically connected to the electronic device.

[0017] Furthermore, the positioning sensor can comprise an electromagnetic shielding body, in particular a metallic shielding plate, and / or a heat sink, in particular a cooling plate. The shielding body and / or the heat sink can be arranged on an outer side of the positioning sensor, in particular between the ribbon cable and the electronic device. The shielding body and / or the heat sink can comprise one or more recesses through which the external lines are routed for connection to the electronic device.

[0018] A stabilizing body, in particular a rigid sleeve, can be arranged around the outer lines at least in the region of the one or more recesses, since the outer lines may not have sufficient stability.

[0019] In a preferred embodiment, the ribbon cable forms a coil with N turns, wherein the positioning sensor has a further coil formed in the same way from another ribbon cable with M turns, in particular with M=N. The two coils are arranged twisted relative to one another, in particular twisted by 90° relative to one another. The two ribbon cables are arranged around one another and cross in a central crossing region. This allows two crossed solenoid coils to be formed. The two ribbon cables are arranged around one another such that the connection points of the individual lines of the second partial end regions of the two ribbon cables do not lie on top of one another.

[0020] Thus, a positioning sensor can be provided in an efficient manner in which a ribbon cable with several individual wires is used to provide the coil winding of the positioning sensor.

[0021] An inductive charging device according to the invention comprises an energy coil for transmitting or receiving energy by induction and a positioning sensor as disclosed herein for generating or detecting a magnetic measuring field for positioning the inductive charging device relative to another inductive charging device. The inductive charging device can be a stationary (primary-side) inductive charging device arranged in or on the ground and generating a magnetic field for inductive energy transfer, wherein the positioning sensor generates the magnetic measuring field for positioning a secondary-side inductive charging device or a vehicle with such an inductive charging device.Alternatively, the inductive charging device can be a mobile (secondary-side) inductive charging device that is arranged in or on the floor of a vehicle and generates a magnetic field for inductive energy transfer, wherein the positioning sensor detects the magnetic measuring field for the positioning of the secondary-side inductive charging device or of the vehicle with such an inductive charging device.

[0022] The ribbon cable has two ends. The positioning sensor can comprise a printed circuit board designed to interconnect the two ends of the N individual lines of the ribbon cable such that the ribbon cable forms N turns of the positioning sensor. Alternatively or additionally, the printed circuit board can be designed to interconnect the two ends of the N individual lines of the ribbon cable such that the N individual lines of the ribbon cable are connected in series (and thus form a single line with N times the length). By using a printed circuit board to couple the individual lines, a positioning sensor can be provided in a particularly efficient manner. The printed circuit board can comprise N first contact points, to each of which the first ends of the N individual lines are connected.In other words, the N individual lines can each be connected at a first end to N first contact points of the circuit board (so that each individual line is coupled to exactly one first contact point). Furthermore, the circuit board can comprise N second contact points, to which the second ends of the N individual lines are each connected. In other words, the N individual lines can be connected at a second end to N second contact points of the circuit board, so that each individual line is coupled to exactly one second contact point. Furthermore, the circuit board can comprise at least (N-1) electrically conductive tracks which are designed to connect the first and second contact points to one another in such a way that N turns are formed by the ribbon cable and / or that the N individual lines are connected in series with one another.By using a printed circuit board, N turns of a (positioning) coil for the positioning sensor can be formed in a particularly efficient and reliable manner.

[0023] The circuit board can comprise a first connection for contacting a first end of a first of the N individual lines. Furthermore, the circuit board can comprise a second connection for contacting a second end of an Nth of the N individual lines. The connections can thus enable contact to both ends of the (positioning) coil. The (positioning) coil formed by the ribbon cable with N turns can be contacted efficiently via the connections, e.g. to feed in an alternating current so that the magnetic measuring field is generated by the positioning sensor, and / or to measure an induced current detected by the positioning sensor. One end is made longer than the other end points. As an example, the first conductor track is extended at the left end and the last conductor track is extended at the right end.All end sections, which are of uniform length, are joined together to form a continuous coil with two extended contact ends. These end sections are referred to as the left end section strand and the right end section strand and are distinguished by their longer design compared to the other conductor tracks. These two end sections can then be routed through the inductive charging device assembly to directly connect the positioning sensor coil to the electronics unit. The connection is ensured by a corresponding interface. This ensures a direct electrical connection from the sensor to the measuring transducer on the electronics unit.

[0024] In a further embodiment of the charging device, the electronics unit has an interface, wherein the interface to the electronics unit is located in the end region of the stranded wire. Interfaces describe the natural boundaries of individual technical systems. Only the connection of the systems to one another, via the interfaces, results in a product. The interface of the stranded wire is the two end regions. These must be connected to the electronics unit. The electronics unit, on the other hand, has, for example, a clamping device through which the end regions of the stranded wire can be clamped. This creates an electrical and mechanical connection between the stranded wire and the electronics unit.

[0025] Both the stationary and the mobile inductive charging unit preferably consist of different layers of different materials that perform different tasks. Examples of these layers include the layer of the stranded wire carrier, in which the high-frequency strand is located. Adjacent to this layer is the layer, which consists of at least one soft magnetic material and is laid, mounted, or glued in one or more parts within this layer.

[0026] Additional layers can be cooling plates, shielding plates, and / or circuit boards for the electronics. Each individual layer prevents the wire from being connected directly to the electronics unit. Solutions are discussed in the prior art that route the contacting over the edge of the charging unit or in the outer casing. Simplified, the wire is connected in the upper cover, and the electronics unit is connected in the lower cover. Electrical contact is established by joining the two covers. Alternatively, the wires are again routed over the edge from the wire carrier layer to the electronics unit layer. This invention discusses the direct route approach, in which each individual layer has the cutout at the same location, allowing the wire to be routed from the wire carrier layer to the electronics unit layer.

[0027] An electronic control unit (ECU) is a microcontroller-based device or component used in various electronic systems to control, monitor, and regulate specific functions. The ECU is usually specifically designed for a particular application and contains electronic circuits, processors, memory, and interfaces. The main function of an ECU is to process input signals, analyze information, and generate appropriate output signals to achieve a desired behavior or function. It does this by executing pre-programmed algorithms and control logic implemented in the ECU. ECUs are used in a wide variety of applications, such as engine control, fuel injection, transmission control, brake control, vehicle stability control, and advanced driver assistance systems.However, ECUs are also used in other areas such as aerospace, medical technology, industrial automation and home appliances.

[0028] An assembly is an assembled unit made up of multiple components or parts that together perform a function. It is a component of a larger system or product. Assemblies can consist of mechanical, electronic, or other components and are commonly used in the manufacturing and engineering industries. The assembly can consist of a variety of individual parts, such as screws, bolts, brackets, cables, circuit boards, chips, or other components. These individual parts are assembled to form a functional unit. The assembly of the assembly can be manual or automated, depending on the requirements and complexity of the assembly.

[0029] The positioning sensor can comprise a coil core, in particular a

[0030] Flux guide element, a ferrite body, and / or a ferrimagnetic body. The ribbon cable can then be wound around the coil core, in particular exactly once. The coil core can have a specific orientation along an axis. The ribbon cable can be wound around this axis around the coil core. By providing a coil core, the directional effect of the positioning sensor can be enhanced, which enables more precise positioning using the positioning sensor.

[0031] The coil core of the positioning sensor can be part of an inductive energy transfer unit (e.g., an inductive primary unit or an inductive secondary unit) of an inductive charging system. The coil core can also be used as the coil core of a (charging) coil for inductive energy transfer. Furthermore, the coil core can be part of the component to be positioned (e.g., the secondary unit) or part of the reference area (e.g., the primary unit). Thus, the coil core of an inductive energy transfer unit can be used for both energy transfer and positioning. This can increase the efficiency of an inductive charging system.

[0032] According to a further aspect, a further positioning sensor is described, which is configured to generate and / or detect a magnetic measuring field for positioning an inductive secondary unit relative to an inductive primary unit. The primary unit can comprise a primary coil configured to generate a magnetic charging field in order to transfer electrical energy to the secondary coil of the secondary unit by means of induction.

[0033] The positioning sensor comprises a coil core or a ferrimagnetic body, which is also used as a coil core for the primary coil or as a coil core for the secondary coil for the inductive transmission of electrical energy. Furthermore, the positioning sensor comprises a positioning coil with N turns surrounding the coil core; where N is an integer with N>0 (e.g., N=5, 10, 20, or more). The positioning coil is configured to generate and / or detect the magnetic measuring field. Thus, a positioning sensor for an inductive charging system is described in which the remote magnetic body used for energy transmission is also used to efficiently adjust the directivity of the positioning sensor. Thus, a cost-, space-, and weight-efficient positioning sensor can be provided.

[0034] The aspects described in this document for a positioning sensor are also applicable to this additional positioning sensor. In particular, the positioning coil with N turns can be efficiently formed by a ribbon cable with N individual wires.

[0035] According to a further aspect, an inductive energy transfer unit for an inductive charging system is described, in which electrical energy is transferred by means of a magnetic charging field over an energy transfer path from a first inductive energy transfer unit (e.g., from a primary unit) to a second inductive energy transfer unit (e.g., to a secondary unit). The inductive energy transfer unit can be the first or the second inductive energy transfer unit.

[0036] The inductive energy transfer unit comprises a ferrimagnetic body or a ferrite or a coil core. The ferrimagnetic body can also be referred to as a ferrite body. The ferrimagnetic body can be substantially cuboid-shaped. Edges of the ferrimagnetic body along a first axis (e.g., the x-axis) can have a length of 30 cm, 40 cm, 50 cm, or more. Furthermore, edges of the ferrimagnetic body along a second axis (e.g., the y-axis) can have a length of 30 cm, 40 cm, 50 cm, or more. Furthermore, edges of the ferrimagnetic body along a third axis (e.g., the z-axis) can have a length of 10 cm, 7.5 cm, 6 cm, or less. The ferrimagnetic body can be designed for an energy transfer path along the third axis (in particular, the z-axis).

[0037] In addition, the inductive energy transfer unit includes a

[0038] An energy transfer coil is arranged locally between the ferrimagnetic body and the energy transfer path. In other words, the energy transfer coil can be arranged along the axis of the energy transfer path next to the ferrimagnetic body. Furthermore, the energy transfer coil can be configured to generate the magnetic charging field (e.g., when the inductive energy transfer unit is the first energy transfer unit) or to generate a charging current in response to the magnetic charging field (e.g., when the inductive energy transfer unit is the first energy transfer unit).

[0039] Furthermore, the inductive energy transfer unit comprises at least one positioning coil with N turns surrounding the ferrimagnetic body, where N is an integer with N>0 (e.g., N=5, 10, 20, or more). As already explained above, the ferrimagnetic body can extend along a first axis and / or along a second axis. The first axis and the second axis are preferably perpendicular to each other. The positioning coil can surround the ferrimagnetic body around the first axis or around the second axis.

[0040] The positioning coil is configured to generate and / or detect a magnetic measuring field for positioning the second inductive energy transfer unit relative to the first inductive energy transfer unit. The positioning sensor formed by the positioning coil typically has an orientation along the first axis when the positioning coil is wound around the first axis. On the other hand, the positioning sensor formed by the positioning coil typically has an orientation along the second axis when the positioning coil is wound around the second axis.

[0041] Thus, an inductive energy transfer unit of an inductive charging system is described, which efficiently provides, in particular through multiple use of the ferrimagnetic body, a positioning sensor for positioning the inductive energy transfer units of the charging system. As already explained above, the ferrimagnetic body can extend along a first axis and / or a second axis. The inductive energy transfer unit can comprise a plurality of positioning coils that enclose the remote magnetic body at a plurality of different locations along the first axis (and are wound around the first axis).

[0042] Alternatively or additionally, the inductive energy transfer unit can comprise a plurality of positioning coils that enclose the remote magnetic body at a plurality of different locations along the second axis (and are wound around the second axis). Thus, a plurality (e.g., 2, 3, 4, or more) positioning sensors can be provided, aligned along the first axis and / or aligned along the second axis. By providing a plurality of positioning sensors, precise positioning of the inductive energy transfer units relative to one another can be enabled.

[0043] The inductive energy transmission unit can thus comprise at least one first positioning coil that surrounds the remote magnetic body around the first axis. Furthermore, the inductive energy transmission unit can comprise at least one second positioning coil that surrounds the remote magnetic body around the second axis. By providing positioning sensors with different directivities or orientations, the quality of the positioning can be improved.

[0044] As already explained above, the inductive energy transfer unit can be the first energy transfer unit or the primary unit. In this case, the energy transfer coil can be configured to generate the magnetic charging field. Furthermore, the at least one positioning coil can be configured to detect the magnetic measuring field for positioning the second inductive energy transfer unit relative to the first inductive energy transfer unit.

[0045] Alternatively, the inductive energy transfer unit can be the second energy transfer unit or the secondary unit. In this case, the energy transfer coil can be configured to generate a charging current in response to the magnetic charging field. Furthermore, the at least one positioning coil can be configured to generate the magnetic measuring field for positioning the second inductive energy transfer unit relative to the first inductive energy transfer unit.

[0046] According to a further aspect, the use of a ribbon cable with N individual lines is described to provide N turns to a positioning sensor, where N is an integer with N> 1. The positioning sensor can be configured to generate and / or detect a magnetic measuring field for the positioning of a component (e.g., a secondary unit or a vehicle) relative to a reference area (e.g., a primary unit).

[0047] According to a further aspect, the use of a remote magnetic body or a coil core of a primary coil or a secondary coil of an inductive charging system as a coil core for a positioning sensor is described. The positioning sensor can be configured to generate and / or detect a magnetic measuring field for positioning the secondary coil relative to the primary coil.

[0048] According to a further aspect, an inductive and / or conductive charging system is described, which comprises one of the positioning sensors described herein. According to a further aspect, a vehicle, in particular a road vehicle (e.g., a passenger car, a truck, a bus, or a motorcycle), is described, which comprises one of the positioning sensors described in this document and / or the inductive energy transfer unit described in this document.

[0049] It should be noted that the methods, devices, and systems described herein can be used both alone and in combination with other methods, devices, and systems described herein. Furthermore, any aspects of the methods, devices, and systems described herein can be combined in a variety of ways. In particular, the features of the claims can be combined in a variety of ways.

[0050] Embodiments of the invention are illustrated in the following drawings and explained in more detail in the following description, wherein like reference numerals refer to like or similar or functionally identical components. They show:

[0051] Fig. 1A an unprocessed ribbon cable;

[0052] Fig. 1 B shows a ribbon cable processed to produce a positioning sensor according to the invention;

[0053] Fig. 1 C shows a positioning sensor manufactured using the ribbon cable shown in Fig. 1 B;

[0054] Fig. 2 shows a second embodiment of a processed ribbon cable;

[0055] Fig. 3 shows a third embodiment of a processed ribbon cable;

[0056] Fig. 4 is a perspective view of the positioning sensor according to the invention shown in Fig. 1C;

[0057] Fig. 5 is a schematic view of the windings of a positioning sensor according to the invention;

[0058] Fig. 6 is a schematic view of another embodiment of a positioning sensor according to the invention;

[0059] Fig. 7 is a schematic view of the connection of the individual lines;

[0060] Fig. 8 shows a schematic structure of an inductive charging unit according to the invention;

[0061] Fig. 9 is a perspective view of another embodiment of a positioning sensor according to the invention with two crossed coils; Figs. 10-12 show various embodiments of a secondary-side charging device according to the invention; and

[0062] Fig. 13-14 various embodiments of a primary-side charging device according to the invention.

[0063] Fig. 1A shows an unprocessed ribbon cable 100, which can be processed to produce a positioning sensor according to the invention. Fig. 1B shows the processed ribbon cable 100. Fig. 1C shows a positioning sensor 200 manufactured using the ribbon cable 100 shown in Fig. 1B.

[0064] The ribbon cable 100 comprises N (four in this example) electrically insulated individual wires 101, 102, 103, 104. N is generally an integer, with N>1. It has two end regions 110, 120, at each of which the N (four) individual wires 101-104 terminate. In the unprocessed state (Fig. 1A), the end regions 110, 120 typically extend along a straight line, such as those created after a ribbon cable is cut.

[0065] In a first processing step, partial regions (shown in dashed lines in Fig. 1A) are separated, for example cut off, at the two end regions 110, 120, resulting in the processed ribbon cable 100 shown in Fig. 1B. There, each end region 110, 120 has two partial end regions 111, 112 and 121, 122, respectively, wherein in each first partial end region 111, 121, a single outer line of the N individual lines ends, which runs along the edge of the respective end region 110, 120. For the partial end region 111, this is the outer line 101 and for the partial end region 121, this is the outer line 104. The first outer line 101 of the first end region 110 thus runs along a first edge region 131 of the ribbon cable 100, which is opposite a second edge region 132 of the ribbon cable 100, along which the second outer line 104 of the second end region 120 runs.The remaining N-1 (in this case, three) individual lines of the N (four) individual lines terminate in a second partial end area 112, 122. Thus, individual lines 102-104 terminate in partial end area 112, and individual lines 101-103 terminate in partial end area 122.

[0066] To form the positioning sensor 200 shown in Fig. 1C, the free end 101a (at the partial end region 111) of the first outer line 101 and the free end 104a of the second outer line 104 are designed for separate electrical connection to an electronic device (not shown). The second partial end regions 112, 122 of the two end regions 110, 120 are connected to one another in such a way that the ends of the remaining N-1 (three) individual lines 102-104 of the first end region 110 ending there are individually electrically connected to the ends of the remaining N-1 (three) individual lines 101-103 of the second end region 120 ending there. This results in a continuous electrical connection, in particular a coil with N turns, from the free end 101a of the first outer line 101 to the free end 104a of the second outer line 104.

[0067] The individual lines of the two end regions terminating in the second partial end regions 112, 122 are individually soldered or welded together, for example, in a dashed connection region 130 in which the two partial end regions 112, 122 overlap. For example, the end of the individual line 103 of the partial end region 122 is electrically connected there to the end of the individual line 104 of the partial end region 112. This type of connection has the advantage that, unlike plug-in connections, it is automotive-compliant and thus certifiable in the automotive sector, particularly since it meets vibration requirements.

[0068] Fig. 2 shows a second embodiment of a processed ribbon cable 100a. Fig. 3 shows a third embodiment of a processed ribbon cable 100b. While in the first embodiment of the ribbon cable 100 shown in Fig. 1B the partial end regions 111, 121 protrude beyond the respective (adjacent) second partial end region 112, 122 of the respective end region 110 or 120, for example over a length in the range of 1 to 10 cm, in the ribbon cable 100a shown in Fig. 1B the partial end regions 111, 121 of the end regions 110, 120 end on a line like the respective second partial end region 112, 122 of the respective end region. In the ribbon cable 100b, the second partial end regions 112, 122 of the end regions 110, 120 protrude beyond the respective first partial end region 111, 121 of the respective end region 110, 120.In this case, the first partial end region 111, 121 is separated from the respective second partial end region 112, 122 along a separation region 113, 123, for example, with a length in the range of 1 to 10 cm. As a result, in these embodiments, the external lines 101 and 104 ending in the first partial end regions 111, 121 can also be separately connected to an electronic device to form the continuous line and thus a coil with N turns.

[0069] To avoid unnecessary waste of material and to minimize the cost of the assembly, it is advisable for the external lines 101 and 104 ending in the first partial end regions 111, 121 to be as short as possible. Ideally, this region is not extended, but rather produced to the length required for the connection. In this case, the material at the second partial end regions that is not required is preferably cut away (see Fig. 1A).

[0070] Fig. 4 shows a perspective view of a positioning sensor 200 according to the invention, as shown in plan view in Fig. 1C. The coil configuration can be seen, in which the two partial end regions 112, 122 are connected to one another in the connecting region 130. Also visible are the two partial end regions 111, 121 with the ends 101a, 104a of the two outer conductors 101 and 104, respectively, at the opposite edge regions 131, 132.

[0071] In other words, a preferred embodiment of a positioning sensor according to the invention essentially comprises a ribbon cable. The ribbon cable has two ends, each of which has a connecting area and can be connected to one another by soldering or gluing. In addition, the ribbon cable has a longer end at each end. These two ends serve to subsequently connect the positioning sensor to the electronics unit. For this purpose, in some applications, the two ends must be guided through a recess, for example, in a shielding body and / or a heat sink, in order to finally connect the sensor to the electronics unit via an interface.

[0072] A positioning sensor can thus comprise multiple turns of an electrical conductor enclosing a coil core or ferrite. Fig. 5 shows an exemplary positioning sensor 300 according to the invention, in which a ribbon cable 301 with N individual lines 306 is efficiently used to provide N turns. In the illustrated example, N=5; generally, N is an integer with N>1, e.g., N=5, 10, 15, 20, or more.

[0073] The ribbon cable 301 has a first end 302 and an opposite second end 303. The two ends 302, 303 can be brought together so that the ribbon cable 301 forms a (possibly single) loop or multiple turns. The connection area 304, in which the individual conductors are electrically connected, is indicated by dashed lines.

[0074] The N turns of a positioning sensor 300 can be wound around a coil core 305, e.g., a flux guide element, a ferrite body, or a ferrimagnetic body, as shown in Fig. 6. This allows for a unique spatial orientation of a positioning sensor 300. In the example shown in Fig. 6, the N turns of the positioning sensor 300 are wound around the y-axis to provide a positioning sensor 300 with a y-direction orientation.

[0075] Ribbon cables can be produced relatively efficiently and are used in mass production in computers and other electronic devices. In particular, ribbon cables are typically significantly more cost-effective than comparable wound individual wires. Ribbon cables already feature individually insulated wires. Furthermore, ribbon cables typically exhibit relatively high mechanical strength. When using a ribbon cable to manufacture a sensor winding, additional structural supports are unnecessary. The ribbon cable can be designed, for example, as a flex cable, flex foil, or FFC cable. Fig.Figure 7 schematically shows how the electrical contacts of the individual wires 101-105 (in the case of five individual wires) are connected to each other, connecting them on the left with those on the right: 101b is connected to 101c, 102b is connected to 102c, 103b is connected to 103c, 104b is connected to 104c, and 105b is connected to 105c. The contacts are deliberately shifted by one contact, so that after connecting both ends, a coil with five turns is formed.

[0076] Fig. 8 shows a schematic structure of an inductive charging unit with its assembly 502, which has a recess 505. Through the recess, the positioning sensor (not shown), i.e. the free ends (101a, 104a, e.g., in Fig. 1C) of the coil windings, can be connected directly to the electronics unit 503 via its interface 504. The assembly 502 can, for example, have an electromagnetic shielding body (e.g., a metallic shielding plate) and / or a heat sink (e.g., a cooling plate). A stabilizing body, in particular a rigid sleeve, can be arranged around each of the outer lines, at least in the region of the recess 502.

[0077] Fig. 9 shows a perspective view of another embodiment of a positioning sensor 400 according to the invention with two crossed coils 410, 420. Both coils 410, 420 are preferably formed in the same way (in particular as described above) and have N or M windings, where M can be N, but M can also be different from N. The two coils 410, 420 are preferably arranged rotated relative to one another, in particular rotated by 90° relative to one another. Furthermore, the two ribbon cables 411, 421, each forming one of the coils 410, 420, are arranged around one another and cross in a central crossing region 405. The free ends of the respective outer conductors 412, 413 and 422, 423 are also visible.

[0078] The two ribbon cables 411, 421 are preferably arranged around each other such that the connection areas 412, 422, i.e., the connection points of the individual lines of the second partial end areas of the two ribbon cables, do not overlap. Preferably, the ribbon cables are preconfigured and inserted around the coil core in the production line, or the coil core is inserted first in the production line and then the connection is soldered or welded.

[0079] Fig. 10, 11 and 12 show several embodiments of inductive charging devices 1, such as can be mounted in particular on the secondary side of vehicles in order to inductively absorb energy from corresponding primary-side charging devices 2 (see Fig. 13 and 14) mounted in or on the ground. The charging devices 1 each have one (or more) energy coil(s) 4 in which current is induced by means of an alternating magnetic field for energy transfer. One or more positioning coils 9a, 9b, 9c, 9d, which are preferably each constructed as described herein, are constructed in the form of solenoid coils around the energy coil(s) and / or flux guide elements 5 (e.g. ferrite plates).They are used to detect separate alternating magnetic fields generated by one or more corresponding positioning coil(s) of the primary-side charging devices, preferably at frequencies other than the frequency of the alternating magnetic fields generated for energy transfer.

[0080] In the embodiment shown in Figs. 10 and 11, two positioning coils 9a, 9b are used that intersect at the center 7, whereby the flux guide elements 5 can each be designed differently. The positioning coils can also not intersect and not extend to the center 7, as shown in Fig. 12 for four positioning coils 9a, 9b, 9c, 9d.

[0081] Such charging devices 1 are described in WO 2023 / 186750 A1, to which reference is hereby explicitly made and the description of which is hereby deemed to be incorporated.

[0082] 13 and 14 show several embodiments of inductive charging devices 2, such as are mounted in particular on the primary side (stationary) in or on the ground in order to inductively transfer energy to a charging device 1 by means of an alternating magnetic field. The charging devices 2 each have one (or more) energy coil(s) 4, with which an alternating magnetic field is generated for energy transmission. One (or more) positioning coil(s) 41, which is preferably constructed as described here, is constructed in the form of a solenoid coil around the energy coil(s) and / or flux guide elements 5 (e.g. ferrite plates). It serves to generate an alternating magnetic field that can be detected by the positioning coils 9a-9d of secondary-side (mobile) charging devices 1.

[0083] Such charging devices 2 are described in WO 2023 / 186749 A1, to which reference is hereby made, and the description of which is hereby incorporated. The solution according to the invention offers the advantages that the complex wrapping of large parts can be eliminated, that vibration requirements in the vehicle can be met, that no installation space is required for automotive-compliant plug connections, and that the complex assembly / insertion of flux guide elements into a pre-assembled coil can be eliminated.

[0084] The present invention is not limited to the embodiments shown. In particular, it should be noted that the description and figures are intended only to illustrate the principle of the proposed methods, devices, and systems.

Claims

Patent claims 1. Positioning sensor (200, 300, 400) for generating or detecting a magnetic measuring field for positioning an inductive charging device or a vehicle with an inductive charging device relative to another inductive charging device, wherein: the positioning sensor comprises at least one ribbon cable (100; 301; 411, 421) which comprises N electrically insulated individual lines (100-104; 306), where N is an integer with N>1; the ribbon cable has two end regions (110, 120) at which the N individual lines each end; each end region has two partial end regions (111, 112;121, 122), wherein in each case a single outer line (101, 104) of the N individual lines ends in a first partial end region (111, 121), which runs at the edge of the respective end region, and in each case the remaining N-1 individual lines of the N individual lines end in a second partial end region (112, 122), wherein the first outer line (101) of a first end region runs at a first edge region (131) of the ribbon cable, which is opposite a second edge region (132) of the ribbon cable, at which the second outer line (104) of a second end region runs; the free end (101a) of the first outer line (101) and the free end (104a) of the second outer line (104) are designed for separate electrical connection to an electronic device (503);and the second partial end regions (112, 122) of the two end regions are connected to one another in such a way that the ends of the remaining N-1 individual lines (102-104) of the first end region (110) ending there are individually electrically connected to the ends of the remaining N-1 individual lines (101-103) of the second end region (120) ending there, thereby resulting in a continuous electrical connection from the free end (101a) of the first outer line to the free end (104a) of the second outer line; REVISED SHEET (RULE 91) ISA / EP 2. Positioning sensor (300) according to claim 1, wherein the first partial end region (111, 121) of one or both end regions projects beyond the second partial end region (112, 122) of the respective end region, in particular over a length in the range of 1 to 10 cm.

3. Positioning sensor according to claim 1, wherein the first partial end region (111, 121) of one or both end regions ends on a line like the second partial end region (112, 122) of the respective end region or the second partial end region of one or both end regions projects beyond the first partial end region of the respective end region, and wherein the first partial end region (111, 121) is separated from the respective second partial end region (112, 122) along a separation region, in particular along a separation region with a length in the range of 1 to 10 cm, from the respective end.

4. Positioning sensor according to one of the preceding claims, wherein the positioning sensor comprises a coil core (305), in particular a flux guide element, a ferrite body and / or a ferrimagnetic body; and wherein the ribbon cable (301) is wound, in particular exactly once, around the coil core (305).

5. Positioning sensor according to claim 3, wherein the coil core (305) is part of an inductive energy transmission unit of an inductive charging system; and / or wherein the coil core (305) is also used as the coil core of a coil for inductive energy transmission.

6. Positioning sensor according to one of the preceding claims, wherein the N individual lines (101 -104; 306) of the ribbon cable (100; 301) REVISED SHEET (RULE 91) ISA / EP are arranged parallel to one another, in particular parallel to one another along a longitudinal extension of the ribbon cable.

7. Positioning sensor according to one of the preceding claims, wherein the second partial end regions (112, 122) of the ribbon cable are glued, welded, fused or soldered together or are connected to one another via an electrically insulating material, in particular via a plastic layer.

8. Positioning sensor according to one of the preceding claims, wherein the ends of the N-1 individual lines of the two second partial end regions (112, 122) are individually soldered or welded together.

9. Positioning sensor according to one of the preceding claims, wherein the positioning sensor comprises an electronic device (503); and wherein the free ends (101a, 104a) of the two outer lines are separately electrically connected to the electronic device.

10. Positioning sensor according to one of the preceding claims, wherein the positioning sensor has an electromagnetic shielding body (502), in particular a metallic shielding plate, and / or a heat sink (502), in particular a cooling plate, wherein the shielding body and / or the heat sink is arranged on an outer side of the positioning sensor, in particular between the ribbon cable and the electronic device.

11. Positioning sensor according to claim 10, wherein the shielding body and / or the heat sink has one or more recesses (502) through which the external lines are guided for connection to the electronic device (503).

12. Positioning sensor according to claim 11, REVISED SHEET (RULE 91) ISA / EP wherein a stabilizing body, in particular a rigid sleeve, is arranged around the outer lines at least in the region of the one or more recesses (502).

13. Positioning sensor according to one of the preceding claims, wherein the ribbon cable (411) forms a coil (410) with N turns; wherein the positioning sensor has a further coil (420) formed in the same way from a further ribbon cable (421) with M turns, in particular with M=N; wherein the two coils are arranged rotated relative to one another, in particular rotated by 90° relative to one another; and wherein the two ribbon cables are arranged around one another and cross in a central crossing region (405).

14. Positioning sensor according to claim 13, wherein the two ribbon cables are arranged around each other such that the connection points of the individual lines of the second partial end regions of the two ribbon cables do not lie on top of each other.

15. Inductive charging device (1, 2) with an energy coil (4) for transmitting or receiving energy by induction; and a positioning sensor (9a, 9b, 9c, 9d; 41) according to one of the preceding claims for generating or detecting a magnetic measuring field for positioning the inductive charging device relative to another inductive charging device.

16. Vehicle with an inductive charging device (2) according to claim 15, wherein the energy coil (4) is designed to absorb energy by means of induction and the positioning sensor (9a, 9b, 9c, 9d) is designed to detect a magnetic measuring field for the positioning of the inductive charging device relative to another inductive charging device (1). REVISED SHEET (RULE 91) ISA / EP

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