Inductive Charging Emergency Shutdown via Redundant Interlock Channels
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Solution Overview
Problem
Existing inductive charging systems for motor vehicles face challenges in reliably and efficiently performing an emergency shutdown, particularly when communication channels are disrupted or system faults occur, leading to potential damage due to overheating or excessive current/voltage, as they rely on primary-side-controlled systems and large, expensive relays.
Innovation Solution
The implementation of redundant communication channels, such as WLAN and point-to-point communication, and the use of contactors to disconnect the motor vehicle drive battery, allowing for efficient and reliable emergency shutdowns by adapting to different fault levels and using a simple inductive signal for safety, along with dual contactors to prevent sticking during high current disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an interrupter relay is used for emergency shutdown, then the charging operation can be discontinued, but the relay becomes hot during normal operation and requires large, expensive HV-switching relays
Solution Approach 1:
The patent extracts the emergency shutdown function from the main power circuit by using a separate communication channel (interlock channel) that can trigger shutdown without carrying power. This separates the control function from the power transmission, allowing the use of smaller, cooler components for shutdown control while maintaining reliability.
Solution Approach 2:
The patent introduces an intermediary communication channel (interlock channel) that mediates between the charging system and the shutdown mechanism. This intermediary allows shutdown commands to be transmitted without requiring the main power relay to handle the shutdown signal, reducing thermal stress on the relay.
2Reliability
If a series relay is used to interrupt charging lines for all poles, then emergency shutdown can be achieved, but all charging lines are interrupted even for minor faults
Solution Approach 1:
The patent segments the charging system into independent poles with individual contactors, allowing selective shutdown of specific charging lines rather than forcing a complete system shutdown. This enables differentiated response to faults in different parts of the system.
Solution Approach 2:
The patent applies partial action by interrupting only the necessary charging lines based on the specific fault condition rather than all lines. The interlock channel enables selective activation of shutdown commands for specific contactors based on the nature and location of the fault.
3Ease of operation
If wireless communication is used for shutdown requests, then the motor vehicle can request immediate shutdown, but communication can be disturbed in emergency cases
Solution Approach 1:
The patent introduces a secondary physical communication channel (interlock channel) as an intermediary backup to the primary wireless communication system. This physical channel provides a reliable fallback mechanism when wireless communication fails during emergencies.
Solution Approach 2:
The patent prepares a backup communication path (interlock channel) in advance that can be activated when the primary wireless communication fails. This cushioning ensures that shutdown capability is maintained even when primary communication is disturbed.
4Object-affected harmful factors
If thermal fuse protection is used in the power electronics system, then overheating protection is provided, but the fuse becomes hot during normal operation
Solution Approach 1:
The patent extracts the overheating protection function from the main power circuit by implementing temperature monitoring and control through the communication system. This allows thermal protection to be achieved without placing a thermal fuse directly in the high-current power path where it would become hot during normal operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, reliable, and cost-effective emergency shutdowns that protect the battery and vehicle architecture by using redundant communication channels and contactors, reducing the need for large HV interrupter relays and preventing damage from faults like overheating or overvoltage.
Implementation Method 1
inductive charging of a motor vehicle having an interrupter relay for the purpose of shutdown... the energy is transmitted by means of the transformer principle over distances of a few centimeters up to approximately 20 cm
Data Source
AI summary
A method and an apparatus for triggering an emergency shutdown of the inductive charging of a secondary-side component in the form of a motor vehicle by a primary-side component in the form of a charging station, includes a plurality of charging system parts of the secondary-side component. The charging system parts are each configured to interrupt at least one switchable communication channel that connects the charging system parts in order to trigger an emergency shutdown of the inductive charging.